Integrated coal drying and steam gasification process

Claim 2

A process for drying an aqueous slurry of carbonaceous solids containing water-soluble gasification catalyst constituents and subsequently gasifying the dried solids which comprises: (a) contacting said aqueous slurry of carbonaceous solids containing said water-soluble gasification catalyst constituents with superheated steam in a fluidized bed drying zone, said superheated steam having a temperature sufficiently higher than the temperature in said drying zone to convert more than about 80 weight percent of the water in said slurry into steam and to deposit said water-soluble gasification catalyst constituents onto said carbonaceous solids; (b) withdrawing carbonaceous solids of reduced water content and impregnated with said gasification catalyst constituents from said drying zone and passing said solids to a gasification zone maintained at gasification conditions; (c) withdrawing steam from said drying zone and passing at least a portion of said steam to said gasification zone; and (d) gasifying said catalyst impregnated carbonaceous solids in said gasification zone with said steam passed to said gasification zone.

Claim 3

A process as defined in claim 1 wherein said carbonaceous solids comprise coal.

Claim 4

A process as defined in claim 1 wherein a portion of said steam withdrawn from said drying zone is superheated and recycled to said drying zone to provide said superheated steam.

Claim 5

A process as defined in claim 1 wherein the aqueous portion of said slurry comprises sour water produced by condensing unreacted steam from the gaseous effluent exiting said gasification zone.

Claim 6

A process as defined in claim 1 wherein said drying zone is maintained at a pressure in the range between the pressure in said gasification zone and about 200 psi above said gasification pressure, and the temperature of the steam withdrawn from said drying zone is maintained between the saturation temperature of steam at the pressure in said drying zone and about 200° F. above said saturation temperature.

Claim 7

A process as defined in claim 1 wherein between about 90 weight percent and about 98 weight percent of the water in said aqueous slurry is converted to steam in said drying zone.

Claim 8

A process as defined in claim 1 wherein said carbonaceous solids removed from said drying zone contain between about 0.1 weight percent and about 10 weight percent water.

Claim 9

A process as defined in claim 1 wherein said aqueous slurry of carbonaceous solids is introduced into the side of said fluid bed slurry dryer at a point at least 5.0 feet above the bottom and said superheated steam is introduced into the bottom of said dryer.

Claim 10

A process for drying an aqueous slurry of carbonaceous solids and subsequently catalytically gasifying the dried solids which comprises: (a) mixing carbonaceous solids with an aqueous solution containing water-soluble gasification catalyst constituents to form said aqueous slurry of carbonaceous solids; (b) contacting said aqueous slurry of carbonaceous solids with superheated steam in a fluidized bed drying zone, said superheated steam having a temperature sufficiently higher than the temperature in said drying zone to convert more than about 80 weight percent of the water in said slurry into steam and to deposit said water-soluble gasification catalyst constituents onto said carbonaceous solids; (c) withdrawing carbonaceous solids having a reduced water content and impregnated with said gasification catalyst constituents from said drying zone and passing said solids to a gasification zone maintained at catalytic steam gasification conditions; (d) withdrawing steam from said drying zone and passing a portion of said steam to said gasification zone; (e) gasifying said catalyst impregnated carbonaceous solids in said gasification zone with said steam passed to said gasification zone to produce char particles containing catalyst residues and a gaseous effluent containing unreacted steam; (f) contacting said char particles with an aqueous leaching agent to form an aqueous solution of water-soluble gasification catalyst constituents; and (g) using said aqueous solution from step (f) in step (a) to form said aqueous slurry of carbonaceous solids.

Claim 11

A process for drying an aqueous slurry of carbonaceous solids and subsequently catalytically gasifying the dried solids which comprises: (a) mixing carbonaceous solids with an aqueous solution containing water-soluble gasification catalyst constituents to form said aqueous slurry of carbonaceous solids; (b) contacting said aqueous slurry of carbonaceous solids with superheated steam in a fluidized bed drying zone, said superheated steam having a temperature sufficiently higher than the temperature in said drying zone to convert more than about 80 weight percent of the water in said slurry into steam and to deposit said water-soluble gasification catalyst constituents onto said carbonaceous solids; (c) withdrawing carbonaceous solids having a reduced water content and impregnated with said gasification catalyst constituents from said drying zone and passing said solids to a gasification zone maintained at catalytic steam gasification conditions; (d) withdrawing steam from said drying zone and passing a portion of said steam to said gasification zone; (e) gasifying said catalyst impregnated carbonaceous solids in said gasification zone with said steam passed to said gasification zone to produce char particles containing catalyst residues and a gaseous effluent containing unreacted steam; (f) contacting said char particles with an aqueous leaching agent to form an aqueous solution of water-soluble gasification catalyst constituents; and (g) using said aqueous solution from step (f) in step (a) to form said aqueous slurry of carbonaceous solids.

Claim 12

A process as defined in claim 9 including the additional steps of condensing said unreacted steam in said gaseous effluent to produce sour water and using at least a portion of said sour water in step (a) to form said aqueous slurry of carbonaceous solids.

Claim 13

A process as defined in claim 10 wherein substantially all of said sour water is used in step (a) to form said aqueous slurry of carbonaceous solids.

Claim 14

A process as defined in claim 9 including the additional steps of condensing said unreacted steam in said gaseous effluent to produce sour water and using at least a portion of said sour water as said aqueous leaching agent in step (f).

Claim 15

A process as defined in claim 12 wherein substantially all of said sour water is used as said aqueous leaching agent in step (f).

Claim 16

A process as defined in claim 9 wherein said carbonaceous solids comprise coal.

Claim 17

A process as defined in claim 9 wherein a portion of said steam withdrawn from said drying zone is superheated and recycled to said drying zone to provide said superheated steam.

Claim 18

A process as defined in claim 15 wherein substantially all of said steam withdrawn from said drying zone that is not superheated and recycled to said drying zone is passed to said gasification zone.

Claim 19

A process as defined in claim 9 wherein substantially all of said steam required in said gasification zone is generated in said drying zone.

Claim 20

A process as defined in claim 9 wherein said gasification catalyst constituents comprise an alkali metal carbonate.

Claim 21

A process for drying an aqueous slurry of coal and subsequently catalytically gasifying the dried coal which comprises: (a) mixing coal with an aqueous solution containing water-soluble gasification catalyst constituents to form said aqueous slurry of coal; (b) contacting said aqueous slurry of coal with superheated steam in a fluidized bed drying zone, said superheated steam having a temperature sufficiently higher than the temperature in said drying zone to convert more than about 80 weight percent of the water in said slurry into steam and to simultaneously deposit said water-soluble gasification catalyst constituents onto said coal; (c) withdrawing coal having a reduced water content and impregnated with said gasification catalyst constituents from said drying zone and passing said coal to a gasification zone maintained at catalytic steam gasification conditions; (d) withdrawing steam from said drying zone; (e) passing a portion of said steam withdrawn from said drying zone through a superheater and recycling it to said drying zone to provide said superheated steam; (f) passing the remainder of said steam withdrawn from said drying zone to said gasification zone; (g) gasifying said catalyst impregnated coal in said gasification zone with said steam passed to said gasification zone to produce char particles containing catalyst residues and a gaseous effluent containing unreacted steam; (h) contacting said char particles with an aqueous leaching agent to form an aqueous solution of water-soluble gasification catalyst constituents; (i) using said aqueous solution from step (h) in step (a) to form said aqueous slurry of coal; (j) condensing said unreacted steam in said gaseous effluent from said gasification zone to produce sour water; and (k) using at least a portion of said sour water in step (a) to form said aqueous slurry of coal.

Claim 22

A process for drying an aqueous slurry of coal and subsequently catalytically gasifying the dried coal which comprises: (a) mixing coal with an aqueous solution containing water-soluble gasification catalyst constituents to form said aqueous slurry of coal; (b) contacting said aqueous slurry of coal with superheated steam in a fluidized bed drying zone, said superheated steam having a temperature sufficiently higher than the temperature in said drying zone to convert more than about 80 weight percent of the water in said slurry into steam and to simultaneously deposit said water-soluble gasification catalyst constituents onto said coal; (c) withdrawing coal having a reduced water content and impregnated with said gasification catalyst constituents from said drying zone and passing said coal to a gasification zone maintained at catalytic steam gasification conditions; (d) withdrawing steam from said drying zone; (e) passing a portion of said steam withdrawn from said drying zone through a superheater and recycling it to said drying zone to provide said superheated steam; (f) passing the remainder of said steam withdrawn from said drying zone to said gasification zone; (g) gasifying said catalyst impregnated coal in said gasification zone with said steam passed to said gasification zone to produce char particles containing catalyst residues and a gaseous effluent containing unreacted steam; (h) contacting said char particles with an aqueous leaching agent to form an aqueous solution of water-soluble gasification catalyst constituents; (i) using said aqueous solution from step (h) in step (a) to form said aqueous slurry of coal; (j) condensing said unreacted steam in said gaseous effluent from said gasification zone to produce sour water; and (k) using at least a portion of said sour water in step (a) to form said aqueous slurry of coal.

Claim 23

A process as defined in claim 19 wherein said aqueous leaching agent comprises fresh water.

Claim 24

A process as defined in claim 19 wherein said aqueous leaching agent comprises at least a portion of said sour water.

Claim 25

A process as defined in claim 19 wherein said aqueous leaching agent comprises substantially all of said sour water.

Claim 26

A process as defined in claim 19 wherein said aqueous leaching agent consists essentially of fresh water and substantially all of said sour water.

Claim 27

A process as defined in claim 23 wherein said aqueous solution of water-soluble gasification catalyst constituents formed in step (h) comprises substantially all of the aqueous portion of the slurry formed in step (a).

Claim 28

A process as defined in claim 19 wherein said gasification catalyst constituents comprise potassium carbonate.

Claim 29

A process as defined in claim 19 wherein the steam passed to said gasification zone in step (f) supplies substantially all of the steam required in said gasification zone and no steam from another source is introduced into said gasification zone.