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US20070000177A1 - Mild catalytic steam gasification process - Google Patents

Mild catalytic steam gasification process Download PDF

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Publication number
US20070000177A1
US20070000177A1 US11/421,507 US42150706A US2007000177A1 US 20070000177 A1 US20070000177 A1 US 20070000177A1 US 42150706 A US42150706 A US 42150706A US 2007000177 A1 US2007000177 A1 US 2007000177A1
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carbonaceous material
gas
trap
methane
steam
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Edwin Hippo
Atul Sheth
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Sure Champion Investment Ltd
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Priority to US11/421,507 priority Critical patent/US20070000177A1/en
Priority to JP2008519394A priority patent/JP2009500471A/ja
Priority to EP06773644A priority patent/EP1910500A2/fr
Priority to KR1020087002593A priority patent/KR20080041635A/ko
Priority to PCT/US2006/024050 priority patent/WO2007005284A2/fr
Priority to BRPI0612806A priority patent/BRPI0612806A2/pt
Priority to CA002612249A priority patent/CA2612249A1/fr
Publication of US20070000177A1 publication Critical patent/US20070000177A1/en
Assigned to GREATPOINT ENERGY, INC. reassignment GREATPOINT ENERGY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HIPPO, EDWIN J, SHETH, ATUL C
Assigned to SURE CHAMPION INVESTMENT LIMITED reassignment SURE CHAMPION INVESTMENT LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GREATPOINT ENERGY, INC.
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/02—Fixed-bed gasification of lump fuel
    • C10J3/06—Continuous processes
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C10J3/463—Gasification of granular or pulverulent flues in suspension in stationary fluidised beds
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C10J3/48—Apparatus; Plants
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
    • C10J3/46—Gasification of granular or pulverulent flues in suspension
    • C10J3/54—Gasification of granular or pulverulent fuels by the Winkler technique, i.e. by fluidisation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2200/00—Details of gasification apparatus
    • C10J2200/15—Details of feeding means
    • C10J2200/158—Screws
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0903—Feed preparation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0913—Carbonaceous raw material
    • C10J2300/093—Coal
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0953—Gasifying agents
    • C10J2300/0969—Carbon dioxide
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0983—Additives
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
    • Y02E20/18—Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]

Definitions

  • the present invention relates to low temperature catalytic gasification of carbonaceous material. More particularly, the present invention relates to an improved process for gasifying carbonaceous material that achieves high carbon conversion to methane at mild temperatures.
  • coal or other carbonaceous materials and steam are reacted with oxygen (or air) to produce a syngas, comprised primarily of hydrogen and carbon monoxide.
  • oxygen or air
  • Syngas comprised primarily of hydrogen and carbon monoxide.
  • Commercial, non-catalyzed, coal gasification systems and designs face a number of economic and technical challenges. These processes are expensive to operate since, in order to drive the endothermic non-catalytic gasification of carbonaceous materials, they utilize severe temperatures (2400 to 2600° F.) and can consume high levels of oxygen. Slagging and corrosion also can present operating and maintenance issues which reduce economic viability and increase product cost.
  • a current concept of an Integrated Gasification Combined Cycle (IGCC) system incorporates a non-catalyzed coal gasification system to produce syngas as an intermediate and burns the syngas to produce electricity.
  • the capital cost of an IGCC system is estimated to range from about $1,250 to $1,400 per KW, depending upon the design and process integration.
  • One way to reduce the cost significantly would be to develop a process that enables one to gasify coal at lower temperature and without added oxygen. Toward this end, it is useful to consider the thermodynamics of gasifying coal.
  • the gasification of coal and similar materials generally involves the following reactions: C+H 2 O ⁇ CO+H 2 (Endothermic) (1) C+2H 2 ⁇ CH 4 (Exothermic) (2) C+CO 2 ⁇ 2CO (Endothermic) (3) CO+H 2 O ⁇ CO 2 +H 2 (Exothermic) (4)
  • the reaction kinetics during conventional (i.e. thermal) gasification generally produce only small amounts of methane.
  • Direct hydrogenation/gasification of carbon such as depicted by equation (2) above is very slow compared to the endothermic reactions of steam and carbon dioxide with carbon, as depicted in equations (1) and (3).
  • the gasification of coal and similar materials thus normally produces a synthesis gas composed primarily of hydrogen and carbon monoxide.
  • the '650 process One such catalytic steam gasification process is disclosed in U.S. Pat. No. 4,094,650 to Koh et al. (“the '650 process”).
  • the preferred temperature and pressure ranges disclosed therein are around 1300° F. (700° C.) and 500 psia (34 atm).
  • Potassium carbonate is disclosed as a preferred catalyst.
  • the temperature is lower than in non-catalyzed gasification, the main raw products are still H 2 and CO.
  • the '650 process teaches recycling the H 2 and CO from the raw product.
  • a catalyst makeup stream is also required in the '650 process because, at the temperatures therein, the alkali metal catalyst can volatilize and/or react with ash constituents of the coal causing a substantial decrease in catalyst activity.
  • methane generation is favored at mild temperatures below about 540° C. and high pressures, but catalytic coal gasification processes typically operate hotter, i.e., at temperatures between about 700° C. to about 820° C., because the gasification rate, and yield, are low in conventional catalytic coal gasification processes at lower temperatures.
  • Mild temperature coal gasification can achieve higher direct conversion of carbon to methane and can reduce or avoid catalyst losses which can occur at higher temperatures due to binding with mineral matter in the carbonaceous feed or volatilization. Mild temperature coal gasification can also minimize the conversion of coal to significantly less reactive char. However, catalysts have not heretofore been identified that can catalyze mild temperature gasification at acceptably high reaction rates.
  • Catalytic metals in combination, can be less vulnerable to deactivation than single-metal catalysts.
  • eutectic catalyst mixtures can maintain catalytic activity longer than one constituent of the mixture.
  • Tandon reported that potassium combined with nickel or iron as a steam/graphite gasification catalyst can remain active longer than iron or nickel alone. It is possible that highly dispersed alkali metal salts can provide a reducing atmosphere for transition metal salts and thus sustain their catalytic activity.
  • CaO or lime can also be used with coal conversion processes to absorb CO 2 .
  • U.S. Pat. No. 4,747,938 to Khan which is directed to coal pyrolysis at about 550° C., discloses that using particulate CaO at up to 25 wt % loading can yield a product stream with less H 2 S and CO 2 .
  • Khan nor the Ohtsuka and Asami processes utilize alkali catalysts.
  • transition metals that can catalyze coal gasification are those which can oscillate between two oxidation states and participate in oxidation-reduction cycles on the carbon surface, and that gasification with alkali metal catalysts involves the alkali metals donating electrons to the carbon lattice, or forming alkali/carbon complexes, thereby increasing the number of active CO complexes on the carbon surface. It is also believed that combinations of such catalysts exhibit sustained activity because different types of active sites on the carbon surface can be activated by different catalytic moieties, making more reaction sites available and reducing the impact of the deactivation of any particular type of reaction site or reaction mechanism.
  • transition metals and alkali metals are catalytically inactive when they are oxidized, and that they can be oxidized by components of the gasification environment such as H 2 O, CO 2 , CO and H 2 S.
  • the alkali metal catalysts can also become inactive or ineffective by volatilizing and/or binding with mineral constituents of coal.
  • Calcium salts and other compounds can react with CO 2 and H 2 S and form solids which can be withdrawn in a solid purge, thereby eliminating or greatly reducing the need to treat the raw gaseous product for acid gas removal.
  • calcium salts can also bind with, and render inert or relatively inert, mineral constituents of the carbonaceous feed so the alkali metal salt catalysts can remain active longer. By preventing such minerals from reacting with and deactivating the alkali metal catalysts, greater catalyst recovery from the solid purge can be achieved and catalyst losses can be reduced. The process can allow for up to ⁇ 90% catalyst recovery.
  • While the invention is not limited to any theory, it is believed that CO 2 in the gasifier causes the catalyst to deactivate, so that by eliminating the CO 2 , high catalytic activity can be sustained and more complete conversion can be achieved.
  • removal of CO 2 from the gas phase can substantially alter the ratio of hydroxide to carbonate forms of the catalyst. Eliminating CO 2 effectively increases the activity of the catalyst and enables a high rate of gasification to occur at mild operating temperatures. At mild temperatures, the kinetics favor greater direct conversion of coal (or other carbonaceous materials) to methane, and the coal, which can convert to less reactive char at conventional catalytic coal gasification temperatures, can remain more reactive. Mild temperature operation can also reduce catalyst losses and corrosion of system components caused by volatilization of the catalyst and hazardous trace elements in the carbonaceous feed.
  • the catalytic gasification processes of the present invention can also be simpler and less costly to build and operate than known prior processes, and can be less prone to overheating, corrosion, char build-up and other problems long associated with other gasification processes and systems.
  • the estimated Btu in, versus Btu out, efficiency can be on the order of 80 to 85% overall.
  • a method for direct catalytic gasification of carbonaceous material to methane comprising causing a reaction of the carbonaceous material in an environment including steam and an alkali metal salt catalyst at mild temperatures in the range from about 300 to about 700° C. and a pressure from about 15 to about 100 atmospheres, and removing CO 2 (and H 2 O) from the products of the reaction in the environment so as to produce a dry raw gaseous product consisting of from about 30% to about 90% methane.
  • the dry raw gaseous product can include at least about 40% methane, or at least about 50%, or at least about 60%, or even at least about 70% methane by volume. This embodiment can be carried out in the absence of or without extensive added or recycled H 2 or CO.
  • Another embodiment provides an improved method for direct catalytic gasification of carbonaceous material to combustible gases, which can be carried out in the absence of added or recycled H 2 or CO, wherein the gasification reaction occurs at a temperature range from about 300 to about 700° C. and a pressure from about 15 to about 100 atmospheres in an environment including steam, an alkali catalyst, and a mineral binder material, and wherein said carbonaceous material includes silica and/or alumina, and other mineral constituents.
  • the mineral binder material can combine with at least a portion of these mineral constituents to inhibit the silica and/or alumina, and other mineral constituents from combining with the alkali catalyst.
  • FIG. 1 is a general Flow Diagram of a Mild Catalytic Coal Gasification (MCCG) Process in accordance with an embodiment of the present invention.
  • MCCG Mild Catalytic Coal Gasification
  • catalyst refers to compositions that are introduced to the process to facilitate the gasification reactions.
  • the term is not meant to be limited to the specific chemical moiety or moieties that activate the carbon surface or otherwise actually participate in the gasification reactions.
  • Standard temperature gasification as used herein, means steam gasification of carbonaceous material at about 550° C. or lower.
  • Synthetically produced fuel gas typically produced from standard coal gasification processes, comprising mostly CO and H 2 by volume.
  • “Dry raw gaseous product” as used herein means non-steam or substantially non-steam products of direct catalytic steam gasification.
  • steam can be a component of the raw gaseous reaction products from direct catalytic steam gasification of carbonaceous materials
  • reference to ‘dry raw gaseous product’ herein means the gaseous products, other than steam, that flow from the gasification reactor and have not been further purified.
  • CO 2 trap material as used herein can be CaO, Ca(OH) 2 , dolomite, limestone, Trona, or other compounds effective for regeneratively combining with CO 2 to form solid carbonates or bicarbonates, and combinations thereof.
  • Mineral binder material as used herein can be a calcium salt, such as CaO, Ca(OH) 2 , CaCO 3 , or any other alkaline earth metal salts which can react with and tie up silica, alumina, and other mineral constituents of the carbonaceous feed so as to inhibit such constituents from reacting with and deactivating the catalyst.
  • the present invention provides a catalytic steam gasification process for converting carbonaceous materials to gases substantially comprising methane or other combustible gases.
  • the process can operate at mild temperatures and produce a dry raw gaseous product that can be used either directly as fuel or purified to pipeline quality methane without the need to remove therefrom substantial quantities of carbon monoxide or acid gases.
  • the process can include a feed preparation zone, a gasification reactor, a catalyst recovery system, and a CO 2 trap regeneration zone.
  • carbonaceous material can be reacted with oxidizing agents such as steam and/or oxygen in the presence of CO 2 trap material, and one or more alkali metal salt catalysts, to produce predominantly methane as the raw product gas.
  • oxidizing agents such as steam and/or oxygen in the presence of CO 2 trap material, and one or more alkali metal salt catalysts
  • the operating temperature in the reactor is below about 550° C.
  • the pressure is in the range from about 12 to about 40 atm.
  • the gasification reactor can have a moving bed or a fluidized bed.
  • Mineral binder material can also be present in the reactor, and can bind with silica, alumina, and other mineral constituents of the carbonaceous feed and thereby prevent or inhibit such constituents from reacting with and deactivating the catalyst.
  • the feed preparation zone can include one or more mixers for combining the carbonaceous material, the alkali metal catalyst, the mineral binder material, and the CO 2 trap material, and a feed system for introducing the catalyst/carbon/CO 2 trap mixture to the gasification reactor as dry solids or as a liquid slurry.
  • the feed system can be a star feeder, screw feeder, or other mechanism effective in maintaining required temperature, pressure and flow rate of the materials to be introduced to the gasification reactor.
  • the carbonaceous material can be coal, heavy oils, petroleum coke, other petroleum products, residua, or byproducts, biomass, garbage, animal, agricultural, or biological wastes and other carbonaceous waste materials, etc., or mixtures thereof.
  • the coal or other carbonaceous material can be ground or pulverized to an average particle size of about 30 to 100 mesh before its delivery for use in the gasification process.
  • Such particles can be impregnated with alkali catalyst in aqueous solution and dried by known methods.
  • the impregnated and dried particles can be mixed with the CO 2 trap material and/or mineral binder material and introduced to the gasifier as a single stream, or such streams can be fed separately, or in combination, as convenient.
  • the carbonaceous materials for use in the process can be more coarse, with an average particle size of about 1-2 mm.
  • Such coarse particles can be combined and ground with an aqueous slurry of finely divided mineral binder material.
  • the resulting paste can be ground with alkali catalyst, dried at about 100° C. with superheated steam to recover a fine powder of carbonaceous material with highly dispersed mineral binder and alkali catalyst having an average particle size of less than roughly 0.02 mm, pelletized to a particle size of about 30-100 mesh, and fed to the gasification reactor.
  • the CO 2 trap material can be combined and fed with the prepared carbonaceous material, or can be fed separately.
  • the CO 2 trap material can be CaO or Ca(OH) 2 , or any other compound that can react with CO 2 to form solid carbonates or bicarbonates, so as to shift the kinetics in the direction of increased methane concentration in the raw gas product.
  • the CO 2 trap material is CaO.
  • Sufficient CO 2 trap material can be used so as to remove substantially all the CO 2 from the products of the reaction to yield a dry raw gaseous product containing less than about 2% CO 2 by volume.
  • the molar ratio of CO 2 trap material to carbon in the reactor can be in the range of about 0.1:1 to about 1:1, or more particularly in the range of about 0.3:1 to about 0.7:1, and more particularly about 0.5:1.
  • the CaO to carbon ratio fed to the reactor can be in the range of about 0.5:1 to about 4:1, or more particularly in the range of about 1:1 to about 3:1, and more particularly about 2:1.
  • the CO 2 trap material can be effective without being highly dispersed on the carbon surface. Thus operating convenience can dictate whether the CO 2 trap material and the carbonaceous feed are mixed and then fed or introduced separately to the gasifier.
  • the alkali catalyst can comprise any of Na 2 CO 3 , K 2 CO 3 , Rb 2 CO 3 , Li 2 CO 3 , Cs 2 CO 3 , KNO 3 , K 2 SO 4 , LiOH, NaOH, KOH, or any suitable alkali metal salts, or naturally occuring minerals containing alkali metal salts such as Trona, or mixtures thereof.
  • the catalyst can be a single compound or a combination of alkali metal salts, which can be binary or ternary salt mixtures.
  • the alkali catalyst loading can be from 1 to 50 weight percent based on the carbonaceous feed on a dry, ash-free basis. Preferably, the alkali loading is in the range of about 1 to 30 wt %.
  • the alkali catalyst can be effective without the presence of any fluorinated compounds.
  • the alkali metal salt catalyst can comprise a eutectic salt mixture of Li 2 CO 3 , Na 2 CO 3 , K 2 CO 3 , Rb 2 CO 3 , and Cs 2 CO 3 or mixtures thereof.
  • the eutectic salt mixture can be a binary salt mixture of about 29% Na 2 CO 3 and about 71% K 2 CO 3 , mole percent.
  • the eutectic salt mixture can be a ternary composition of about 43.5% Li 2 CO 3 , 31.5% Na 2 CO 3 and 25% K 2 CO 3 , mole percent, or a ternary salt mixture of about 39% Li 2 CO 3 , 38.5% Na 2 CO 3 and 22.5% Rb 2 CO 3 , mole percent.
  • the mineral binder material can be a compound or a mixture of compounds selected from the group consisting of CaO, Ca(OH) 2 , CaCO 3 , and other alkaline earth metal salts.
  • the mineral binder can be kneaded or otherwise dispersed on the carbonaceous feed particles in a feed pretreatment step before the alkali catalyst is contacted with the carbonaceous feed.
  • kneading calcium salts with the carbonaceous feed particles can be used to help prevent mineral interactions with the alkali metal catalyst.
  • the carbonaceous feed, the mineral binder, and alkali catalyst can be mixed together simultaneously by conventional methods.
  • the mineral binder material can be fed separately to the gasifier and/or mineral binder material can form in the gasifier, wherein such mineral binder material (e.g., CaCO 3 ) can react with silica, alumina, and other mineral constituents present in the carbonaceous feed and prevent or inhibit some alkali catalyst loss and deactivation.
  • mineral binder material e.g., CaCO 3
  • the mineral binder can combine with at least a portion of any reactive mineral constituents in the carbonaceous feed such as aluminum and silicon constituents, and thereby prevent or inhibit such reactive mineral constituents from reacting with the alkali catalysts.
  • the mineral binder material can thus be effective at stoichiometric quantities about equal to that of the reactive mineral constituents in the carbonaceous feed.
  • the carbonaceous feed material is Illinois #6 coal which contains on a dry basis about 10 to 11 wt % ash of which silica comprises about 51 wt % and alumina comprises about 18 wt %
  • 7.1 tons of CaCO 3 or the equivalent amount of another mineral e.g., about 4.0 tons of CaO
  • the amount of CaO utilized can be in the range of about 2 to 6 wt % and is preferably highly dispersed with the feed; whereas to promote CO 2 trapping, higher amounts in the range of 50 to 200 wt %, which need not be highly dispersed with the feed can be utilized. It is expected that substantial amounts in the range of at least 60% to about 90% of the CO 2 trap material can be recovered in the CO 2 trap regenerator and recycled within the process, such that the amount of fresh CO 2 trap material can be about 5 to 80 wt % CaO.
  • the feed can include about 5% CaO highly dispersed within the feed and the balance as a separate stream.
  • the reactor is designed so that a solid purge can be periodically or continuously withdrawn.
  • the CO 2 trap material reacts with CO 2 in the reactor and is withdrawn in the “carbonated” form with the solid purge.
  • the solid purge can include particles of CaCO 3 , as well as particles of unreacted carbon, the ash or mineral constituents of the carbonaceous feed, and some alkali catalyst in various forms.
  • the process of the invention can include a regeneration process of conventional design to recover and recycle active CO 2 trap material, if desired or necessary.
  • the CO 2 trap material is CaO
  • the CO 2 trap material regenerator can be a calciner.
  • CaCO 3 particles can be separated from said withdrawn solids by passing through a coarse sieve, or by elutriation of fine particles or other techniques, and can be directed to the calciner to recover the CaO.
  • the recovered CaO can be activated or its surface area increased by steam treatment or similar treatment, during or after calcination and prior to recycling.
  • the regenerated CaO recycled to the gasifier can constitute as much as about 90% of the calcium value withdrawn in the solid purge.
  • the calcined off-gas mostly CO 2 and possibly some CaCO 3 , CaS and CaSO 4 , as well as H 2 S and possibly SO 2 and O 2 , can be sequestered or otherwise properly disposed.
  • the solid purge fraction that passes through the sieve can include soluble alkali metal salts, and can also include insoluble alkali and/or calcium aluminosilicates. These can be treated in a catalyst recovery system for recovery and recycle of the catalyst.
  • the catalyst recovery system can comprise a water wash system and optionally can comprise a lime digestion system.
  • the hot carbon/ash particles can be contacted with water and soluble catalyst constituents of the particles can dissolve into solution. If the particles contain small amounts of alkali aluminosilicates, then the water contacting step can be sufficient to accomplish essentially complete catalyst recovery.
  • the washed solids can be digested in an alkaline solution or slurry to recover insoluble alkali moieties.
  • the washed solids can contain sufficient calcium or other alkaline compounds such that little or no additional lime or other alkaline solution is necessary for digestion.
  • the partial pressure and/or concentration of steam can be monitored and controlled to maximize conversion rates and maximize overall conversion to methane or other desired gaseous product such as syngas.
  • causing the reaction includes maintaining a molar ratio of steam to carbon in the range of about 1.5 to 3 and/or controlling partial pressure of the steam by addition of a non-reactive gas to the gasification environment.
  • the catalytic steam gasification process can produce a dry raw gaseous product that includes at least about 40% methane and can include at least about 50%, or at least about 60%, or even at least about 70% or higher, methane by volume, without the need for H 2 and CO recycling, or extensive recycling, and without the need for separate stage water-gas shift reactions.
  • Other embodiments produce a dry raw gaseous product that can include about 80% methane or higher.
  • the overall direct carbon conversion of carbonaceous material to methane can be at least about 50%, more particularly at least about 65%, still more particularly at least about 80%, and still more particularly at least about 90%. In still more particular embodiments, the carbon conversion of the carbonaceous material can be at least about 50% or at least about 65% at less than about 550° C.
  • alkali metal salts compliment transition metal salts in that they keep them active for longer reaction times.
  • the active catalyst state may actually contain three metals (two outside catalysts and one from the mineral in coal).
  • coal can be gasified at low temperatures and elevated pressures to produce methane, and that lower temperatures help to minimize syngas formation.
  • FIG. 1 A process flow diagram for the envisioned low temperature steam gasification process, mild catalytic coal gasification (MCCG), is shown in FIG. 1 .
  • MCCG mild catalytic coal gasification
  • Particulate coal or other carbonaceous material, particles of CO 2 trap material and/or mineral binder material, and an alkali metal catalyst solution can be combined and mixed in mixer 100 to form a feed stream and fed to one or more lock hoppers shown generally as lock hopper 200 .
  • Said particulate streams can be fed separately to mixer 100 or combined (not shown) before being fed to mixer 100 .
  • the feed stream can be fed to gasifier 300 by a screw feeder 250 , which alternatively can be a star feeder, or a mechanism that feeds the carbonaceous material as a liquid slurry, or any other feed mechanism known in the art which allows carbonaceous material to be fed to a gasifier at a rate, temperature and pressure necessary to achieve the desired gasification result.
  • a screw feeder 250 which alternatively can be a star feeder, or a mechanism that feeds the carbonaceous material as a liquid slurry, or any other feed mechanism known in the art which allows carbonaceous material to be fed to a gasifier at a rate, temperature and pressure necessary to achieve the desired gasification result.
  • Gasifier 300 can be operated in a fluid bed 400 A or a moving bed 400 B mode.
  • Advantages of fluid bed mode 400 A include ease of design and easy tar control.
  • One disadvantage of the fluid bed is that fresh feed particles of coal and the CO 2 trap material may be removed with converted residue (solid purge).
  • the steam concentration in the outlet gas will be higher than in the moving bed.
  • the moving bed mode is more complex because solid recycle is needed to move partially gasified coal to the top of the bed to prevent tar from leaving the reactor with the product gas.
  • an advantage of the moving bed is that the steam concentration in the outlet gas will be substantially reduced and attrition of the CO 2 trap material is minimized. This mode also maximizes coal conversion.
  • such compounds can react with and tie up minerals in the coal or other carbonaceous material, preventing or inhibiting the minerals from reacting with the alkali metal salt catalysts so the alkali metal salt catalysts will remain active longer, increasing the carbon conversion efficiency and carbon conversion rate and improving catalytic recovery.
  • such compounds can react with alumina, silica, or other mineral constituents of the coal.
  • the coal or other carbonaceous feed can also be pretreated with CaO, Ca(OH) 2 , CaCO 3 , or other alkaline earth metal salts to tie up the minerals/ash in the coal.
  • Gasifier 300 is operated at about 550° C. or less and at an operating pressure of less than about 1000 psig (68 atm).
  • CaO, Ca(OH) 2 , or other compounds effective for regeneratively combining with CO 2 can be used as a trap for CO 2 and sulfur gases. This will enhance catalytic activity by driving the reaction forward and will also enhance production of methane by shifting the reaction kinetics toward increased production of methane.
  • Steam is fed to the bottom of gasifier 300 . It can be beneficial to add a small quantity of O 2 /air to the steam to activate the catalyst. In such embodiments, between about 0.1% to 3% oxygen or air is added to the steam to provide oxidized sites on the coal surface and provide complexes where catalyst can interact with the coal to produce higher gasification rates and carbon conversion.
  • Product gases will leave the top of gasifier 300 and pass through a condenser 500 to remove steam.
  • the condensed water can be used within the catalyst recovery system 600 .
  • the product gases, mostly CH 4 with lesser amounts of H 2 and NH 3 can be diverted for separation (not shown) using traditional methods, as needed. Gas separation will be dependent on target product end use. If desired, syngas is produced by lowering pressure and reducing CaO feed (or other CO 2 trap) to control the H 2 /CO ratio.
  • Spent residue leaves the bottom of reactor/gasifier 300 and is separated ( 700 ) by a screen or other device to separate the larger sized CaCO 3 particles, which form when CaO or Ca(OH) 2 is used as the CO 2 trap material.
  • the smaller sized residue is fed to extractor/catalyst recovery system, shown generally as 600 , where the catalyst is dissolved, concentrated (if necessary) and recycled. Residue from extractor 600 then goes to waste, perhaps landfill, or for by-product utilization after determination of hazard waste potential.
  • the calcium carbonate is calcined in calciner 800 and recycled to mixer 100 .
  • the calcined off gas, (mostly CO 2 and possibly some particulate CaCO 3 , CaS and CaSO 4 as well as H 2 S and possibly SO 2 and O 2 ) is ready for sequestration if the system is operated under pressure.
  • coal or other carbonaceous material; a CO 2 trap material such as CaO or Ca(OH) 2 particles; and an alkali metal catalyst solution are mixed in mixer 100 , fed to lock hopper 200 , and fed to gasifier 300 as described above.
  • Mixer 100 can comprise an impeller and means to heat the contents such that the carbonaceous particles can become impregnated with alkali catalyst therein.
  • Gasifier 300 can be operated in a fluid bed 400 A or a moving bed 400 B mode, as described, and is operated at a temperature between about 300° C. about 700° C. and a pressure from about 12 to about 40 atm.
  • CaO or Ca(OH) 2 can be used as a trap for CO 2 and sulfur gases, and CaO, Ca(OH) 2 , CaCO 3 , or other alkaline earth metal salts can react with alumina, silica, or other mineral constituents of the coal.
  • Carbon conversion rate for steam gasification of Powder River Basin coal (PRB) was studied in the temperature range of 500° C. and 700° C. Carbon conversion without catalyst was about 60% after 15 minutes at 700° C. and increased to about 75% after 30 minutes. With KOH catalyst, the conversion increased to about 65% and 85% respectively. Interestingly, with KOH catalyst and CaO/C loading of 1:2 molar (about 2:1 weight ratio), conversion increased to about 95% irrespective of the reaction time. Thus, with the CaO trap material, the coal conversion is essentially complete in just about 15 minutes, showing that a gasification reactor for these conditions can be designed for a short residence time and achieve good conversion.
  • the effect of temperature can be shown by comparing the conversion after 30 minutes at 650° C., 600° C., and 550° C.
  • the uncatalyzed conversion was about 70% at 650° C., and decreased to about 50% at lower temperatures.
  • KOH catalyst the conversion was about 80% at 650° C. and decreased to about 65% and about 60% at 600° C. and 550° C. respectively.
  • KOH and CaO loaded at CaO/C of 1:2 molar as above
  • the conversion at 650° C. was better than that observed at 700° C., which was about 95%.
  • Carbon conversion rate for steam gasification of petroleum coke was studied at 700° C. and 650° C. Carbon conversion without catalyst at 700° C. was about 35% after 15 minutes and only increased to about 45% after 60 minutes and about 55% after 90 minutes. With KOH catalyst, the conversion increased to about 45% after 15 minutes, and to about 55%, 60%, and 80% after 30, 60, and 90 minutes respectively. With KOH catalyst and CaO (again loaded at 1:2 molar CaO/C), conversion increased to about 85% after 15 or 30 minutes and to about 95% after 60 or 90 minutes. The corresponding conversions at 650° C. and 60 minutes, were 15% for uncatalyzed petroleum coke, about 50% with KOH, and about 80% with the CO 2 trap. The increase in conversion with the CO 2 trap at 650° C. indicates that steam gasification of petroleum coke at 650° C. can be economically feasible.
  • Carbon conversion for catalytic steam gasification in the temperature range of 500° C. and 700° C. of Powder River Basin coal (PRB) in the presence of KOH, LiOH, NaOH, and Ca(OH) 2 was measured.
  • the conversion with KOH was about 90% and 85% respectively at 700° C. and 650° C., and decreased to about 70% at 600° C. and to about 60% at 550° C. and 500° C.
  • NaOH showed significantly better performance of about 80% conversion at 600° C. and 70% at 550° C., and performed about the same as KOH at 700° C., 650° C. and 500° C. This suggests NaOH as a preferred low cost catalyst for low temperature steam gasification.
  • the conversion with LiOH was 5 to 10% lower than with NaOH, except at 500° C. where LiOH gave about 65% conversion compared to about 60% conversion with NaOH, KOH, or Ca(OH) 2 .
  • the conversion with Ca(OH) 2 was about 70% at temperatures from 700° C. to 550° C., and dropped below 60% at 500° C.
  • coal is mixed with an alkali metal catalyst, and calcium salts selected from CaO, Ca(OH) 2 , CaCO 3 and other alkaline earth metal salts as described above, and then mixed with petroleum residua.
  • the coal/residua mixture is heated to about 400 to 500° C. for about 3 to 30 minutes to disperse the catalyst, and then is gasified and further processed as described above.
  • Dispersing the catalyst allows for better catalyst contact, allowing temperatures to be dropped to about 300° C. to about 550° C. Such dispersal also provides better contact and reaction between reactive mineral components of the carbonaceous feed and such alkaline earth salts, thereby avoiding mineral/catalyst interactions and enhancing catalyst recovery. Dispersal also allows for more efficient sulfur removal, reduced catalyst quantities, and enables extensive gasification to result in only unreactive solids and minerals remaining after gasification is complete. In particular embodiments, the coal to residua weight ratio is in the range of about 1:1 to about 1:10.
  • the four feed components can be combined first into two streams, one comprising coal and calcium salts, and the other comprising alkali catalyst and residua; and such combined streams can then be mixed together and heated, as above, to about 400 to 500° C. for about 3 to 30 minutes to disperse the alkali catalyst onto the coal.
  • a small amount of residua can be combined with the coal, blended with the catalyst, and then blended with the balance of the residua.
  • the coal/residua/catalyst mixture is then introduced into a reactor at the dispersing temperature described above (400 to 500° C.) for about 3 to 30 minutes as described, and the dispersed mixture is introduced into another reactor where steam is added. Gasification is then done with steam to produce gases (methane, ethane, propane and butane) and light distillate C5 to C10 fraction (gasoline fraction).
  • gases methane, ethane, propane and butane
  • light distillate C5 to C10 fraction gasoline fraction

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JP2008519394A JP2009500471A (ja) 2005-07-01 2006-06-21 温和な接触水蒸気ガス化法
EP06773644A EP1910500A2 (fr) 2005-07-01 2006-06-21 Procede de gazeification a la vapeur catalytique modere
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PCT/US2006/024050 WO2007005284A2 (fr) 2005-07-01 2006-06-21 Procede de gazeification a la vapeur catalytique modere
BRPI0612806A BRPI0612806A2 (pt) 2005-07-01 2006-06-21 método para gaseificação catalítica de material carbonáceo em gases combustíveis
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WO2007005284A2 (fr) 2007-01-11
BRPI0612806A2 (pt) 2016-11-29

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