There isn't a lot conceptually new in the document we submit to your attention herein.
As we've reported many times, as for one instance in:
West Virginia Coal Association | Pittsburgh Converts Coal Ash and Flue Gas into Cement | Research & Development; concerning: "United States Patent 5,766,339 - Producing Cement from a Flue Gas Desulfurization Waste; 1998; Assignee: Dravo Lime Company, Pittsburgh; Abstract: Cement is produced by forming a moist mixture of a flue gas desulfurization process waste product containing 80-95 percent by weight calcium sulfite hemihydrate and 5-20 percent by weight calcium sulfate hemihydrate, aluminum, iron, silica and carbon, agglomerating the moist mixture while drying the same to form a feedstock, and calcining the dry agglomerated feedstock in a rotary kiln. Sulfur dioxide released from the calcium sulfite hemihydrate and calcium sulfate hemihydrate during calcination may be used to produce sulfuric acid, while heat recovered in the process is used to dry the agglomerating feedstock. Claims: A process for producing cement from a flue gas desulfurization process waste product, comprising: providing a moist flue gas desulfurization process waste product containing 80-95 percent by weight of solids of calcium sulfite hemihydrate and 5-20 percent by weight of solids of calcium sulfate hemihydrate; adding a source of aluminum, iron, carbon, and a siliceous material to said flue gas desulfurization process waste product to form a moist mixture thereof; agglomerating said moist mixture while removing water therefrom, by contact with hot air, to provide a dry agglomerated kiln feedstock containing about 6 percent or less water; calcining said dry agglomerated kiln feedstock in a rotary kiln to produce a cement clinker; and pulverizing said cement clinker to produce cement. The process for producing cement from a flue gas desulfurization process waste product ... wherein said source of aluminum and iron comprises fly ash";
all of the solid residua resulting from our essential use of Coal in the generation of abundant and truly affordable electric power can be productively consumed in the manufacture of Portland-type cement.
Further, as seen in our reports of:
West Virginia Coal Association | WVU & Canada Cement from Coal Liquefaction Residues | Research & Development; concerning: "US Patent Application 20120090510 - Forming Cement as a By-Product of Coal Liquefaction; 2012; Inventor: Alfred H. Stiller, Morgantown, WV; Assignee: Quantex Research Corporation, Calgary, Canada; Abstract: The present disclosure provides methods and systems for coal liquefaction and obtaining a cement by-product"; and:
West Virginia Coal Association | Exxon Converts Coal Conversion Residues to Cement | Research & Development; concerning: "United States Patent 4,260,421 - Cement Production from Coal Conversion Residues; 1981; Assignee: Exxon Research and Engineering Company, New Jersey; Abstract: Cement is produced by feeding residue solids containing carbonaceous material and ash constituents obtained from converting a carbonaceous feed material into liquids and/or gases into a cement-making zone and burning the carbon in the residue solids to supply at least a portion of the energy required to convert the solids into cement";
the same is true of the mineral residua resulting from the conversion of our abundant Coal, through both gasification or direct liquefaction processes, into substitutes for natural liquid and gaseous hydrocarbons.
And, we further confirm that fact herein, via excerpts from the initial link in this dispatch to:
"United States Patent 4,174,974 - Process for Converting Coal Ash Slag into Portland Cement
Process for converting coal ash slag into portland cement
Date: November 20, 1979
Inventor: Frederick F. Fondriest, IL
Assignee: Standard Oil Company of Indiana, Chicago
Abstract: Disclosed is a manufacturing process for converting coal ash slag from a slagging coal gasifier into a marketable cement product having the characteristics and qualities of portland cement. This process comprises the steps of transferring molten slag from a slagging coal gasifier to a melt chamber and reacting it with a mineral containing lime, for example: calcium oxide, calcium hydroxide or calcium carbonate, to form a homogeneous cement product. This cement product is then transferred to a quench chamber where it is allowed to cool and solidify in the form of clinkers, which are later reduced to powder form. This process also provides an efficient means to conserve energy when producing a portland cement and provides an effective and economical way to dispose of a waste product while increasing the cost efficiency of a slagging coal gasifier.
(First, lest there be any doubts about why Standard Oil might want to consider gasifying Coal in a "slagging coal gasifier", see, for a few examples, our reports of:
West Virginia Coal Association | Standard Oil 1949 Coal + Steam = Hydrocarbon Syngas | Research & Development; concerning: "United States Patent 2,482,187 - Producing Hydrogen-Carbon Monoxide Mixtures; 1949; Assignee: Standard Oil Company, Chicago; Abstract: This invention relates to a process and apparatus for the optimum utilization of the hydrocarbon values derived from solid carbonaceous substances such as coal ... . ... the invention pertains to the production of gas mixtures comprising essentially hydrogen and carbon oxides suitable for the synthesis of hydrocarbons. The method of making gas mixtures consisting chiefly of hydrogen and carbon monoxide suitable for the synthesis of hydrocarbons"; and:
West Virginia Coal Association | Standard Oil 1952 Coal to Gasoline Emits No CO2 | Research & Development; concerning: "United States Patent 2,620,348 - Hydrocarbon Synthesis with Two-Stage Coke Gasification; 1952; Assignee: Standard Oil Development Company; Abstract: The present invention relates to the catalytic reaction between carbon monoxide and hydrogen to form valuable liquid products, and more specifically to a novel process for the preparation of synthesis gas. More particularly, the present invention is concerned with improvements in the reaction based upon an improved two-stage process for preparing synthesis gas from coke or coal, and a two-stage process for reacting synthesis gas thus produced to give high yields of valuable high octane gasoline, preferably at low synthesis pressures"; and:
West Virginia Coal Association | Standard Oil 1953 Syngas from Coal, CO2 and Cellulose | Research & Development; concerning: "United States Patent 2,644,745 - Production of Gases from Carbonaceous Solids; 1953; Assignee: Standard Oil Development Company; Abstract: The present invention relates to the conversion of carbonaceous solids into combustible gases. More specifically, the invention is concerned with the gasification of all types of coal (and) cellulosic materials ... to produce ... gas mixtures containing CO and H2 suitable for the catalytic synthesis of hydrocarbon and oxygenated compounds".)
Claims: A manufacturing process for converting coal ash slag from a slagging coal gasifier into a marketable cement product having the characteristics and qualities of portland cement, which process comprises the steps of: transferring molten bituminous, semi-bituminous or lignitic noncoking coal slag having a temperature range between approximately 2800 F and 3600 F from a slagging coal gasifier to a melt chamber, reacting a preheated mineral containing lime with said slag in the ratio of 1 part slag to 1.2 to 4 parts of said mineral containing lime to form a homogeneous cement product having a temperature range between approximately 2200 F and 2800 F, transferring said cement product to a quench chamber where said product cools and solidifies in the form of clinkers, and reducing said clinkers to powder form.
The process ... wherein said mineral containing lime is calcium oxide (or) calcium carbonate.
(Plain old limestone, i.e., "calcium carbonate", is just fine, in other words.)
The process ... wherein said ratio of slag to mineral containing lime is 1 part of slag to 2.5 parts of said lime containing material.
(We do, though, need rather more limestone than Coal conversion slag. Conventional Cement kilns are using a whole lot of limestone, anyway, though; so, what difference does it make? We still productively utilize Coal conversion slag herein, while conserving some natural raw materials and energy. The use of any limestone at all will generate Carbon Dioxide through the CaCO3 + Heat = CaO + CO2 reaction. But, in light of technologies like that seen, for just one example, in our report of:
West Virginia Coal Association | Iceland, August 2012, CO2 to Gasoline and Diesel | Research & Development; concerning: "US Patent Application 20120201717 - Process and System for Producing Liquid Fuel from CO2 and Water; 2012; Assignee: CRI, Iceland; Abstract: A process and system for producing high octane fuel from carbon dioxide and water is disclosed. The feedstock for the production line is industrial carbon dioxide and water, which may be of lower quality. The end product can be high octane gasoline, high cetane diesel";
so what?)
A manufacturing process for converting coal ash slag from a slagging coal gasifier into a marketable cement product having the characteristics and qualities of portland cement, which process comprises the steps of:
(a) transferring molten bituminous, semi-bituminous or lignitic noncoking coal slag from a slagging coal gasifier to a melt chamber;
(b) reacting a preheated mineral containing lime, such as calcium oxide, calcium hydroxide or calcium carbonate, with said molten slag in said melt chamber in the ratio of about 1 part of slag to 1.2 to 4 parts of said mineral containing lime to form a conglomerate;
(c) stirring said conglomerate until a homogeneous cement product is formed;
(d) transferring said cement product to a quench chamber where said product cools and solidifies in the form of clinkers;
(e) adding a set regulating additive to said clinkers, and
(f) reducing said composition to powder.
The process ... wherein said set regulating additive is gypsum.
(And, as in, for just one example, our report of:
West Virginia Coal Association | Pennsylvania Improves Use of Coal Flue Gas Gypsum | Research & Development; concerning: "United States Patent 5,362,471 - Producing Gypsum Flake from Flue Gas Desulfurization; 1994; Assignee: Air Products and Chemicals, Incorporated, Allentown (PA); Abstract: This invention relates to an improved process for producing gypsum calcium sulfate dihydrate flakes from powdered gypsum calcium sulfate dihydrate obtained from the desulfurization of flue gas by the wet limestone process";
we can obtain the needed "gypsum", as well, as a byproduct from Coal combustion for the generation of economical electric power.)
Background and Field: The present invention relates to a manufacturing process for converting coal ash slag into a marketable cement product having the characteristics and qualities of portland cement. This process comprises the steps of transferring molten slag from a slagging coal gasifier to a melt chamber, reacting a mineral containing lime, for example: lime, quicklime or limestone, with said slag in the ratio of one part of slag to 1.2 to 4 parts of the mineral containing lime to form a homogeneous cement product, and transferring the cement product to a quench chamber where it cools and solidifies into clinkers. After hardening, a set regulating additive, such as gypsum or anhydrite, is combined with the clinkers and this composition is ground into powder, whereby it is ready for present or future use.
Presently, the world is in a situation where energy has become a major consideration and the cost of producing it has steadily increased. Because of the foreseeable shortage of clean burning fuels, such as gas and oil, and due to the increasing cost of such fuels, more industries will have to rely much more heavily on coal as a source of energy. This greater use of coal presents both ecological and technological problems since coal usually burns less cleanly than either gas or oil. Moreover, since coal-driven locomotives and ships have almost disappeared from the scene, coal can scarcely serve at all as a fuel for vehicles.
Success in exploiting the world's huge reserves of coal therefore depends on the development of a technology that will convert coal into oil and gas on a large scale. Such technology is currently available in the way of coal gasifiers, with the four principal methods being: carbonization, direct hydrogenation, extraction process, and Fischer-Tropsch Synthesis.
Generally speaking, coal gasification involves the reaction of coal, at high temperatures, with a gas containing oxygen and steam to produce a gas substantially comprising CO and H2, which is suitable for use as a fuel. As a byproduct of gasification, a char or slag component is produced which must be disposed of. This disposal problem is compounded by the fact that the slag has limited value as a structural material and yet a substantial quantity is produced which must somehow be discarded. Depending upon the type and source of coal, the ash or slag content may vary from 5 to 50 percent by weight. This percentage becomes significant for a gasifier which handles 100,000 lbs./hr.
Accordingly, there is a present need and there will be a greater future need for large volume uses of coal ash slag.
Cement is one of the largest energy consuming products made today and because cement is of such a relatively low value, it is advantageous to conceive of a process which requires less energy.
As used herein, a hydraulic cement refers to a material that will harden in the presence of water and is capable of uniting particles or masses of other solid matter into a concrete mass. In the United States most of the hydraulic cement used in construction is portland cement.
(The) most energy-intensive step in portland cement manufacture is the kiln operation. Although electric power is required for kiln rotation, only fossil fuels are used to generate the 2700 F temperature required to convert the raw material into clinkers.
It can readily be envisioned that a substantial energy saving can be obtained if molten slag from a coal gasifier could be reacted with a lime containing material to produce portland cement.
It is the general object of this invention to provide a process for converting coal ash slag into a usable product having the characteristics and qualities of portland cement.
It is an object of this invention to provide a process for making portland cement from the slag of a coal gasifier.
It is further an object of this invention to provide a more efficient energy saving way to produce portland cement.
It is still further an object of this invention to provide a useful method for disposing of coal slag.
Summary: This invention relates to a manufacturing process for converting coal ash slag from a slagging coal gasifier into a marketable cement product having the characteristics and qualities of portland cement. The process comprises the steps of transferring molten coal ash slag having a temperature range between approximately 2800 F and 3600 F from a coal gasifier to a melt chamber, reacting a mineral containing lime, for example lime, quicklime, or limestone, with said slag in the ratio of 1 part of slag to 1.2 to 4 parts of said mineral containing lime to form a homogeneous cement product having a temperature range between approximately 2200 F and 2800 F, transferring said cement product to a quench chamber wherein said product cools and solidifies in the form of clinkers, and adding a set regulating additive, such as anhydrite or gypsum, before the mixture is ground to powder.
This process has the advantage of providing an efficient way to conserve energy when producing portland cement and also provides an effective and economical way to dispose of a waste product while increasing the cost efficiency of a slagging coal gasifier."
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Thus, we can "conserve energy" by using the "molten coal ash slag" from a Coal gasification process, which is converting Coal into a "gas substantially comprising CO and H2" intended for use in the "Fischer-Tropsch Synthesis", to indirectly "convert coal into oil and gas", to make "a marketable cement product having the characteristics and qualities of portland cement". All of which serves to increase "the cost efficiency of" producing that "CO and H2" hydrocarbon synthesis gas, from which both liquid and gaseous hydrocarbon fuels can be made via the specified "Fischer-Tropsch Synthesis".
There's not much else by way of comment that seems appropriate for inclusion herein.
Clearly, the petroleum industry, as represented in this case by the Standard Oil Company of Indiana and their successors and assigns, knows how to convert our abundant domestic Coal into any and all of the various liquid and gaseous hydrocarbons that have become essential to our modern way of United States life, and which we now find ourselves economically enslaved to the inimical, alien powers of OPEC to keep ourselves supplied with in the here and now.
And, we can reduce the economic and environmental costs, we can increase the profitability, of utilizing our Coal for such applications, by utilizing the mineral residues of it's conversion into hydrocarbons in the manufacture of Portland Cement, an application that conserves both energy and other natural raw material resources, and reduces, through a couple of different routes, the amount of CO2 ordinarily co-produced in the cement-making process.
We have the knowledge in hand.
All that seems lacking is the will to disseminate that knowledge publicly and, then, to use it.