We have many times documented the fact that Methane can be synthesized from Coal, as well as from, via the Sabatier process, Carbon Dioxide.
We have also, in the course of our reportage, occasionally noted that Sulfur, as is, unfortunately, often found in Coal, can be detrimental to catalysts employed to convert synthesis gas, derived via the hydro-gasification of Coal, into Methane and other hydrocarbon products.
Herein, we see that a, somewhat unlikely, major corporation developed, more than thirty-three years ago, an improved catalyst for converting Sulfur-containing synthesis gas into Methane, one that could withstand concentrations of Sulfur which might remain in Coal-derived syngas after economical, but less that 100% effective, Sulfur removal procedures were undertaken on that syngas.
Comment again emphasizing the rather vast utility of Methane follows excerpts from:
"United States Patent 4,002,658 - Methanation Catalyst and Process of Using Same
Date: January, 1977
Inventor: Ralph Dalla Betta, et. al., MI
Assignee: Ford Motor Company, Dearborn
Abstract: This application teaches a methanation catalyst in which nickel is employed on a zirconium oxide substrate. This catalyst may be used in a methanation process in which the feed gases to the process contain between about 10 to 100 ppm (parts per million) of sulfur.
Claims: A method of methanating a synthesis gas stream including a sulfur bearing component in a concentration in a range from 10 ppm to 100 ppm which comprises: passing said synthesis gas stream over a nickel catalyst formed on a catalyst substrate principally of zirconium oxide.
(And) wherein: said synthesis gas stream is obtained by gasification of coal ... .
(And) wherein said synthesis gas stream is subjected to a single sulfur removal operation prior to the methanation operation.
It is an object of this invention to provide a methanation catalyst which is not easily poisoned by sulfur.
It is a further object of this invention to provide a methanation process in which the gas fed to the process can contain in the range from 10 to 100 ppm of sulfur and can contain substantially higher sulfur levels for short periods of time.
In accordance with another aspect of this invention, a synthesis gas stream prepared by gasifying coal is processed to remove sulfur therefrom by a single sulfur removal operation. The resulting synthesis gas stream contains in a range from 10 to 100 ppm of sulfur. This synthesis gas is passed over a methanation catalyst in which the substrate is zirconium oxide and the catalyst material is nickel. Even at the relatively high sulfur concentrations of 10 to 100 ppm, the methanation process is effective to produce substantial quantities of methane gas from the feed gas."
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So, we can manufacture "substantial quantities of methane gas from" a "synthesis gas ... obtained by gasification of coal", wherein that Coal-derived syngas needs only "a single" and thus, presumably, economical "sulfur removal operation prior to the methanation operation".
We don't, in other words, have to utilize high-grade, and, thus, higher-cost, low-Sulfur Coal to synthesize Methane.
And, once we have that Methane, synthesized from economical grades of Coal, we are sending along report today of United States Patent Application: 0090205254; wherein scientists in Australia tell us what we can do with it: react it in a tri-reforming process, such as previously explained by Penn State University, as we've documented, with Water and Carbon Dioxide, and thereby synthesize liquid hydrocarbon fuels.