CA2653348A1 - Catalytic steam gasification process with recovery and recycle of alkali metal compounds - Google Patents

Catalytic steam gasification process with recovery and recycle of alkali metal compounds Download PDF

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Publication number
CA2653348A1
CA2653348A1 CA002653348A CA2653348A CA2653348A1 CA 2653348 A1 CA2653348 A1 CA 2653348A1 CA 002653348 A CA002653348 A CA 002653348A CA 2653348 A CA2653348 A CA 2653348A CA 2653348 A1 CA2653348 A1 CA 2653348A1
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CA
Canada
Prior art keywords
stream
compounds
solids
solution
alkali
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002653348A
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French (fr)
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CA2653348C (en
Inventor
Atul C. Sheth
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Greatpoint Energy Inc
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Greatpoint Energy, Inc.
Atul C. Sheth
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Publication of CA2653348A1 publication Critical patent/CA2653348A1/en
Application granted granted Critical
Publication of CA2653348C publication Critical patent/CA2653348C/en
Expired - Fee Related legal-status Critical Current
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Classifications

    • 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
    • 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
    • C10J2300/0983—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
    • C10J2300/09—Details of the feed, e.g. feeding of spent catalyst, inert gas or halogens
    • C10J2300/0983—Additives
    • C10J2300/0986—Catalysts
    • 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
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1625—Integration of gasification processes with another plant or parts within the plant with solids treatment
    • C10J2300/1628—Ash post-treatment
    • C10J2300/1631—Ash recycling
    • 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
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1696—Integration of gasification processes with another plant or parts within the plant with phase separation, e.g. after condensation
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Abstract

A high efficiency gasification process for converting carbonaceous solids to methane and apparatus for its practice are described. The process includes reacting steam and carbonaceous solids comprising ash in the presence of alkali metal catalyst in a gasification reactor to produce combustible gases and char particles comprising ash and alkali metal catalyst constituents, treating a stream of such char particles in an alkali metal catalyst recovery system to recover the catalyst constituents as alkali metal compounds, and recycling such recovered compounds. Within the alkali metal catalyst recovery system the process includes quenching the stream of char particles with water whereby such particles are cooled and fractured, dissolving soluble alkali metal catalyst constituents from the fractured solids to form a first alkali metal catalyst solution and washed solids, optionally reacting the washed solids in alkaline solution to form a second alkali metal catalyst solution, upgrading said first and optional second alkali solution to recover the alkali metal catalyst constituents as said alkali metal compounds.

Claims (19)

1. A coal gasification process comprising:

contacting coal particles with steam in the presence of an alkali metal catalyst in a reactor wherein raw product gases are formed and char particles are produced, said char particles containing carbon, inorganic constituents, and alkali metal catalyst constituents, withdrawing a stream of said raw product gases from said reactor, recovering a product gas stream from said stream of said raw product gases, contacting a stream of char particles from said reactor with water in a fracturing unit whereby said char particles fracture and a portion of said alkali metal catalyst constituents dissolve into said water to form a fracturing unit solution and washed solids, withdrawing from said fracturing unit a stream of said washed solids and a stream of said fracturing unit solution.
2. The process of claim 1 wherein said stream of washed solids is reacted with a solution of alkaline earth compounds at a temperature in the range of about 50°C to about 300°C to form a slurry of spent solids, and the process further comprises:

combining said slurry of spent solids with said stream of fracturing unit solution to form a catalyst recovery stream, filtering and carbonating said catalyst recovery stream to recover a stream of alkali carbonate compounds, and recycling said alkali carbonate compounds for contacting with said coal particles.
3. The process of claim 2 wherein said slurry of spent solids is not treated to multi-stage water wash prior to recycling alkali carbonate compounds recovered therefrom.
4. The process of claim 1 further comprising:

filtering and carbonating said stream of fracturing unit solution to recover a stream of alkali carbonate compounds, and recycling said alkali carbonate compounds for contacting with said coal particles.
5. The process of claim 4 wherein said stream of fracturing unit solution is not treated to multi-stage water wash prior to recycling alkali carbonate compounds recovered therefrom.
6. The process of claim 2 or 4 wherein said alkali carbonate compounds comprise potassium carbonate or sodium carbonate.
7. The process of claim 2 wherein said solution of alkaline earth compounds comprises calcium hydroxide, and the molar ratio of calcium hydroxide to alkali metal in the washed solids is from about 5 to about 25.
8. The process of claim 2 or 4 wherein said carbonating follows said filtering.
9. The process of claim 2 or 4 wherein said carbonating is conducted by exposing said catalyst recovery stream to a stream comprising carbon dioxide.
10. The process of claim 1 wherein said product stream comprises methane.
11. The process of claim 1 wherein said product stream comprises syngas.
12. The process of claim 1 wherein said contacting a stream of char particles from said reactor with water in a fracturing unit comprises water jets impinging upon said stream of char particles.
13. The process of claim 1 wherein said contacting a stream of char particles from said reactor with water in a fracturing unit comprises said stream of char particles falling into a pool of water.
14. The process of claim 2 or 4 wherein said alkali carbonates are recycled as an aqueous solution.
15. The process of claim 2 or 4 further comprising drying said stream of alkali carbonate compounds and recycling said alkali carbonate compounds as solids.
16. The process of claim 1 wherein said stream of water washed solids is withdrawn at a temperature in the range of about 50°C to about 300°C.
17. The process of claim 16 wherein said stream of water washed solids is withdrawn at a temperature in the range of about 50°C to about 95°C.
18. The process of claim 16 wherein said stream of water washed solids is withdrawn at a temperature in the range of about 125°C to about 300°C.
19. A process wherein carbonaceous solids containing alumina and silica constituents are reacted in the presence of alkali metal compounds to form char particles which comprise insoluble alkali compounds and soluble alkali compounds said process comprising:

contacting a stream of said char particles with water in a fracturing unit whereby said particles fracture and a portion of said soluble alkali compounds dissolve to form washed solids and a first solution comprising said portion of soluble alkali compounds, and wherein said washed solids settle, digesting a stream of said settled, washed solids with a solution or slurry of alkaline earth compound in aqueous phase to form a slurry of spent solids comprising alkaline earth compounds in a second solution comprising a portion of said insoluble alkali compounds, combining said a slurry of spent solids comprising alkaline earth compounds in said second solution with said first solution to form a catalyst recovery stream, filtering and carbonating said catalyst recovery stream to recover a stream of alkali carbonate compounds, and recycling said alkali carbonate compounds for use in said process.
CA2653348A 2006-06-01 2007-05-18 Catalytic steam gasification process with recovery and recycle of alkali metal compounds Expired - Fee Related CA2653348C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US11/421,511 2006-06-01
US11/421,511 US7922782B2 (en) 2006-06-01 2006-06-01 Catalytic steam gasification process with recovery and recycle of alkali metal compounds
PCT/US2007/069265 WO2007143376A1 (en) 2006-06-01 2007-05-18 Catalytic steam gasification process with recovery and recycle of alkali metal compounds

Publications (2)

Publication Number Publication Date
CA2653348A1 true CA2653348A1 (en) 2007-12-13
CA2653348C CA2653348C (en) 2012-02-28

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Family Applications (1)

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CA2653348A Expired - Fee Related CA2653348C (en) 2006-06-01 2007-05-18 Catalytic steam gasification process with recovery and recycle of alkali metal compounds

Country Status (9)

Country Link
US (1) US7922782B2 (en)
EP (1) EP2038377A1 (en)
JP (1) JP5193194B2 (en)
CN (1) CN101484554B (en)
AU (1) AU2007256969B2 (en)
CA (1) CA2653348C (en)
EA (1) EA200870600A1 (en)
WO (1) WO2007143376A1 (en)
ZA (1) ZA200809986B (en)

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AU2007256969A1 (en) 2007-12-13
US7922782B2 (en) 2011-04-12
ZA200809986B (en) 2009-11-25
AU2007256969B2 (en) 2010-05-20
WO2007143376A1 (en) 2007-12-13
US20070277437A1 (en) 2007-12-06
CN101484554A (en) 2009-07-15
JP5193194B2 (en) 2013-05-08

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