Over the long course of our reportage, we've many times described, made reference to, and documented the now nearly-ancient "Fischer-Tropsch synthesis", wherein a blend of Carbon Monoxide and Hydrogen, originally stipulated to made by the gasification of Coal, as explained for one example in our report of:
West Virginia Coal Association | WV DuPont 1954 Coal and Steam to Hydrocarbon Syngas | Research & Development; concerning: "United States Patent 2,698,227 - Preparation of Synthesis Gases from Carbonaceous Solids; 1954; Inventor: Luther Peery, et. al., Charleston, WV; Assignee: E.I. du Pont de Nemours and Company, DE; This invention relates to a process for the preparation of synthesis gases by the partial oxidation of comminuted solid carbonaceous materials, and is more particularly directed to the preparation of hydrogen, gaseous mixtures containing ... hydrogen and carbon monoxide by the partial oxidation of powdered coal";
is catalytically, chemically condensed into a range of hydrocarbons, all the way from substitute natural gas Methane to a heavy hydrocarbon tar.The basic Fischer-Tropsch chemical condensation process is explained by the Volkswagen Group, via:
Volkswagen Group - Fischer-Tropsch Synthesis; wherein they tell us: "In Fischer-Tropsch synthesis, hydrogen and carbon monoxide react to form long-chained hydrocarbons. It is based on the following catalytic chain-growth reaction: CO + 2H2 = (-CH2-) + H2O. The reaction occurs x-times. A straight chain of x -CH2- components is formed. If the chain, for example, consists of 16 CH2 components, this hydrocarbon is called n-hexadecane or also commonly cetane ... a very important component of diesel fuel".
The Fischer-Tropsch synthesis results in the production of a range of hydrocarbons, via the intermediate generation of synthesis gas, as in the above-cited "United States Patent 2,698,227 - Preparation of Synthesis Gases from Carbonaceous Solids", from Coal, and, as people are becoming increasingly aware, as seen in:
West Virginia Coal Association | California Hydrogasifies Coal & Carbon-Recycling Wastes | Research & Development; concerning: "US Patent 7,500,997 - Steam Pyrolysis ... to Enhance the Hydro-Gasification of Carbonaceous Materials; 2009; Assignee: The Regents of the University of California; Abstract: A process and apparatus for producing a synthesis gas for use as ... feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. In one embodiment, a slurry of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor to generate methane rich producer gases which are fed into a steam pyrolytic reformer to generate synthesis gas comprising hydrogen and carbon monoxide (and) wherein the carbonaceous material comprises municipal waste, biomass, wood, coal, or a natural or synthetic polymer";
from all sorts of, some renewable, biological products and from organic, Carbon-containing wastes in addition to Coal.
Further, as we perhaps first documented more than three and half years ago via:
West Virginia Coal Association | WVU Makes Alcohol from Coal for USDOE | Research & Development; concerning: "'The Economical Production Of Alcohol Fuels From Coal-Derived Synthesis Gas'; Contract No. DE-AC22-91PC91034; (1998); (For) U.S. Department of Energy; Pittsburgh Energy Technology Center,
Pittsburgh, PA; (By) West Virginia University Research Corporation on behalf of West Virginia University,
Morgantown, WV 26506";
we're also able to catalyze the synthesis of other products, perhaps most especially various Alcohols, depending upon the catalyst and processing conditions employed, from such hydrocarbon syngas. .
We'll note in passing that the original link(s) we included in that report, to US Government electronic archives of the West Virginia University document, "The Economical Production Of Alcohol Fuels From Coal-Derived Synthesis Gas", might no longer function as they did or should. It can now, though, be accessed via:
http://www.osti.gov/scitech/
And, we remind you that, as explained by the University of Akron, in our report of:
West Virginia Coal Association | The University of Akron Improves Coal to Gasoline Process | Research & Development; concerning: "'A Novel Synthesis Route for Liquid Fuels from Coal-derived Syngas'; The University of Akron, Akron, Ohio (and) Electric Power Research Institute; Palo Alto, California; Abstract: Coal-derived syngas can be converted to methanol using Liquid Phase Methanol Synthesis Process. Methanol can be further converted to gasoline using the Mobil Methanol-To-Gasoline (MTG) process. The combination of commercial syngas-to-methanol technology with the MTG Process thus provides a ready synthetic route for liquid hydrocarbon fuels. We have developed a novel process for one-step synthesis of Dimethyl Ether (DME) from syngas. This DME Synthesis improves the reactor productivity and syngas conversion, by as much as 100% over LPMeOH (Liquid Phase Methanol) Process. One-step DME synthesis is thus an ideal front-end for further conversion to gasoline";
the conversion of syngas first into Alcohol, might enable the production more specifically of Gasoline from Coal and other Carbon-containing raw materials, as opposed to the original Fischer-Tropsch synthesis which results in a much cruder mix of hydrocarbons that require further refining.
And, herein we learn that not only is the technology for synthesizing various products from blends of Hydrogen and Carbon Monoxide hydrocarbon synthesis gas being improved, but, so are the designs and operation of the equipment for making that synthesis gas from some of our abundant Coal.
Note that the focus of the invention herein is the management, or rather the capture, of the inorganic mineral content of the Coal being gasified as a slag, which can be more easily captured and extracted from the gasification reactor, rather than allowing the discharge of the mineral matter as fly ash, which is not only more environmentally problematic, but which could interfere with downstream processes, like hydrocarbon synthesis via the Fischer-Tropsch technology, by clogging or fouling catalyst surfaces,
As seen in excerpts from the initial link in this dispatch to the recently-awarded:
"United States Patent 8,562,698 - Device for Production of Synthesis Gas with a Gasification Reactor with a Subsequent Quenching Space
(Syngas - Wikipedia, the free encyclopedia; "Syngas, or synthesis gas, is a fuel gas mixture consisting primarily of hydrogen, carbon monoxide, and very often some carbon dioxide. The name comes from its use as intermediates in creating synthetic natural gas(SNG) and for producing ammonia or methanol. Syngas is also used as an intermediate in producing synthetic petroleum for use as a fuel or lubricant via the Fischer-Tropsch process.")
October 22, 2013
Inventor: Johannes Kowoll, Germany
Assignee: ThyssenKrupp Uhde, GmbH, Germany
(Make no mistake. ThyssenKrupp Uhde is a genuinely significant, sophisticated corporation with a global reach and a focus on energy issues. More about them and their gasification technologies, of which our subject, "United States Patent 8,562,698", is only the latest example, can be learned via:
http://www.thyssenkrupp-uhde.
wherein they further illuminate the potentials for synthesizing Substitute Natural Gas and hydrocarbon liquids, via the Fischer-Tropsch synthesis, from both Coal and CO2-recycling Biomass. And, the benefits, in terms of cost and emissions, of such Coal and Biomass co-gasification and conversion shouldn't be ignored, as explained by the USDOE in our report of:
West Virginia Coal Association | USDOE Coal + Biomass = Affordable, Low-Carbon Liquid Fuel | Research & Development; concerning: "'Affordable, Low-Carbon Diesel Fuel from Domestic Coal and Biomass'; 2009; DOE/NETL-2009/1349; Energy Systems Engineer Office of Systems, Analyses, and Planning National Energy Technology Laboratory".
Even more about ThyssenKrupp Uhde's advanced and efficient gasification technologies can be learned via an informative marketing brochure:
http://www.thyssenkrupp-uhde.
which we will forward a file of separately to the West Virginia Coal Association.)
Abstract: The invention relates to a device for producing a crude gas containing CO or H2 by gasification of an ash-containing fuel with oxygen-containing gas at temperatures above the fusion temperature of the ash in a gasification reactor and with a connected gas cooling chamber and a tapered connecting channel running from one chamber to the other. The aim of the invention is avoiding known problems and reducing the amount of fly ash and the amount of ungasified fuel, wherein a weak eddy is achieved in the inlet to the subsequent apparatuses in order to avoid deposits there with a very compact device, wherein the risk of solidification of the slag in the outlet is also avoided. The aim is achieved, wherein in the tapered connection channel eddy reducing or eliminating wall surfaces running over only a part of the cross-section of the connection channel are provided.
Claims: An apparatus for production of raw gas that contains CO and H2, by means of gasification of fuel that contains ash, with gas that contains oxygen, at temperatures above the melting temperature of the ash, comprising: a gasification reactor; a subsequent gas cooling space; a transition channel between the gasification reactor and the gas cooling space, the transition channel having a diameter that is less than a diameter of the reactor and the cooling space; and separate installations in the form of a plurality of cooling pipes provided in the transition channel, the installations being adapted to reduce or prevent spin of process gases, the installations passing through only a part of the cross-sectional area of the transition channel, to form a narrowed interior that is free of installations, the lengths of the installations being between 0.5 and 4 times the diameter of the transition channel, wherein the transition channel is equipped, at its lower end, in the direction of gravity, with a constriction having a drip edge, wherein the constriction is additionally surrounded, at the transition channel, by a mixing pipe having a free edge at a bottom end thereof, to form an additional mixing space, and wherein a resulting expansion angle between the drip edge and the free edge of the mixing pipe lies in the range of 10 to 30 degree(s).
Description: The invention is directed at a device for production of raw gas that contains CO and H2, by means of gasification of fuel that contains ash, with gas that contains oxygen, at temperatures above the melting temperature of the ash, in a gasification reactor, and with a subsequent gas cooling space and a transition channel that narrows from one space into the other.
In the case of gasifiers having a conventional design, 30 to 60% of the fuel ash is generally converted to flue ash, and this brings with it the disadvantages that deposits form in the raw gas path, and increased erosion of subsequent apparatuses can occur. The deposition and removal of flue ash are clearly more complicated and expensive than that of slag. Disposal of the flue ash is also more expensive, since heavy metals can be contained in parts of the flue ash, and furthermore this is generally fine dust that cannot be disposed of in the open.
It is known that a spin in the gasifier first deflects the gas streaming out of the burner plane against the wall, thereby causing part of the flue ash to be precipitated at the wall and the dwell time of the fuel particles in the gasifier to be extended. It is also known that the stronger the spin, the more intensive the substance exchange in the gasifier. In this connection, stronger precipitation of the ash occurs. However, as already mentioned briefly above, a high spin in the gasifier exit causes difficulties in subsequent apparatuses, since the hot gases and slag particles are accelerated in the direction of the walls at a high tangential velocity. For this reason, only a slight spin is preferred in the gasifier, for example a firing angle of 3 degree(s). This is where the invention takes its start, whose task consists not only of avoiding the disadvantages (of described prior art Coal gasifiers), but also of reducing the amount of flue ash and the amounts of the non-gasified fuels, whereby only a weak spin is supposed to be achieved in the entry of the subsequent apparatuses, in order to avoid deposits there, with a very compact device, whereby the risk of solidification of the slag in the run-out is not supposed to occur.
This task is accomplished, according to the invention, with a device of the type indicated initially, in that wall surfaces that reduce or prevent spin and pass through only a part of the cross-section of the transition channel are provided in the narrowed transition channel. It has been shown that these wall surfaces, which are configured to be comparatively narrow, can optimally be used as spin brakes, without unnecessarily reducing the size of the passage cross-section of the transition channel.
Because of the "spin brake" according to the invention, it is possible to provide a firing angle of 5 to 10.degree. with reference to the corresponding secant of the burner array, along with other spin bodies and installations for achieving increased circulation in the gasifier and thus intensive mixing, as the invention also provides (and, the) fuel reaction is increased by means of this measure, and caking of the ash particles is reinforced, thereby also improving the precipitation of these particles.
Finally, it is possible to continuously determine the heat flow (by methods described; and, if )the heat flow density is too great, ... then the amount of oxygen can be reduced, for example, or the amount of the moderation gas (H2O or CO2) can be increased."
-------------------------
We'll close our excerpts there, since by far the bulk of the disclosure, as you can likely surmise, is given over to fairly detailed description of the gasifier and it's operation, all of which really requires illustration for a full understanding and appreciation.
But, note, in the final excerpted statement, the implied use, as in, for just one example, our report of:
West Virginia Coal Association | Conoco 2011 Coal + CO2 + H2O + O2 = Syngas | Research & Development; concerning: "United States Patent 7,959,829 - Gasification System and Process; 2011; ConocoPhillips Company, Houston; A system and process for gasifying carbonaceous feedstock with staged slurry addition in order to prevent the formation of tar that causes deposition problems (and) wherein said carrier liquid is selected from group consisting of water, liquid Carbon Dioxide, (or) mixtures thereof";
of Carbon Dioxide as one of the agents of Coal gasification, along with, for the supply of Hydrogen, H2O.
That, coupled with the information available through the links we included above to ThyssenKrupp's info about the co-gasification, with Coal, of Biomass, should provide you with strong indications about the sustainability of indirect Coal conversion systems like the one disclosed herein; which really, in it's essence, is mostly about the management of the mineral, or ash, constituent of Coal during gasification, and it's efficient recovery as a slag, rather than as fly ash which could clog up the system, so to speak, and foul the hydrocarbon synthesis catalysts to which the produced syngas would likely be directed. And, the gasification reactor disclosed herein could thus likely be referred to as a "slagging" Coal gasifier; and, as seen in our report of:
West Virginia Coal Association | Standard Oil Converts Coal Conversion Residues into Cement | Research & Development; concerning: "United States Patent 4,174,974 - Process for Converting Coal Ash Slag into Portland Cement; 1979; 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";
the slag could still be suitably used and consumed in the making of Portand-type Cement. And/or, since, as seen in:
West Virginia Coal Association | China Extracts More Aluminum from Coal Ash | Research & Development; concerning: "United States Patent 8,568,671 - Method for Preparing Metallurgical-Grade Alumina by Using Fluidized Bed Fly Ash; 2013; Assignee: China Shenhua Energy Company Limited, Beijing (China); Abstract: Provided a method for preparing metallurgical-grade alumina by using fluidized-bed fly ash, comprising: a) removing iron by wet magnetic separation after crushing the fly ash";
even Fly Ash needs to be crushed prior to processing it as an ore of Aluminum, the slag recovered from the process of our subject herein, "United States Patent 8,562,698 - Device for Production of Synthesis Gas with a Gasification Reactor with a Subsequent Quenching Space", could be similarly treated and then combined with Coal combustion ash in an Aluminum ore extraction process.