Method of catalytic gasification with increased ash fusion temperature

Claim 1

A process for producing a gaseous product comprising hydrogen and carbon monoxide by high ash fusion temperature catalyzed gasification of bituminous coal at temperatures at least 100° F. above the initial deformation temperature without substantial ash fusion comprising the sequence of steps as follows: (a) providing a mixture consisting essentially of 50 to 80 weight percent finely divided bituminous coal particles of a size of 65 mesh or smaller than 65 mesh and 20 to 50 weight percent finely divided calcium compound particles of a size smaller than 65 mesh, said calcium compound being selected from the group consisting of calcium oxide, calcium carbonate and calcium hydroxide, said bituminous coal having the property of becoming liquid with sufficient heating, (b) briquetting said mixture to form a briquetted mixture, (c) feeding said briquetted mixture into the top of a fixed bed gasifier, (d) catalytically gasifying said briquetted mixture with steam in said gasifier to form a gaseous product comprising hydrogen and carbon monoxide, said hydrogen and said carbon monoxide each comprising a substantial portion of said gaseous product, said gasifying comprising (i) heating said briquetted mixture of finely divided coal and finely divided calcium compound in said fixed bed gasifier to an operating temperature at least 100° F. above the intial deformation temperature of the ash of said bituminous coal and, said heating forming a catalyzed coke, said catalyzed coke reacting with said added steam to form said gaseous product, (ii) adding steam to said gasifier, said operating temperature being below the initial deformation temperature of the ash of said mixture of said bituminous coal and said calcium compound, whereby said calcium compound catalyzes said gasification, the rate of said catalyzed gasification being substantially increased from the rate of uncatalyzed gasification of said bituminous coal, and said catalyzed gasification being without ash fusion.