U.S. patent number 3,759,036 [Application Number 05/119,820] was granted by the patent office on 1973-09-18 for power generation.
This patent grant is currently assigned to Chevron Research Company. Invention is credited to Robert J. White.
United States Patent |
3,759,036 |
White |
September 18, 1973 |
**Please see images for:
( Certificate of Correction ) ** |
POWER GENERATION
Abstract
A process for gasifying waste material and producing energy
which comprises contacting a solid organic waste material
containing at least 10 weight percent oxygen with steam in the
presence of an alkali metal carbonate catalyst at an elevated
temperature to obtain a gas, combusting at least a portion of said
gas to obtain combusted gases, and expanding the combusted gases
through a turbine to rotate the turbine. Preferably, the energy of
the rotating turbine is used to drive an electricity generator. It
is strongly preferred to use a potassium carbonate catalyst in the
gasification of the oxygen-containing waste material. Preferably
feedstocks include ordinary municipal refuse or garbage having the
requisite oxygen content and usually having a more preferred oxygen
content above at least 20 weight percent oxygen.
Inventors: |
White; Robert J. (Pinole,
CA) |
Assignee: |
Chevron Research Company (San
Francisco, CA)
|
Family
ID: |
22386593 |
Appl.
No.: |
05/119,820 |
Filed: |
March 1, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
34834 |
May 5, 1970 |
|
|
|
|
Current U.S.
Class: |
60/775; 48/209;
60/39.12; 210/758 |
Current CPC
Class: |
C10J
3/00 (20130101); C01B 3/22 (20130101); F02C
3/28 (20130101); C10K 1/004 (20130101); F23G
5/46 (20130101); C01B 3/40 (20130101); C10K
1/005 (20130101); F23G 5/027 (20130101); C10K
3/04 (20130101); C10J 2300/165 (20130101); C10J
2300/1846 (20130101); Y02P 20/145 (20151101); Y02E
20/18 (20130101); C01B 2203/1047 (20130101); Y02E
20/12 (20130101); Y02T 50/60 (20130101); Y02E
50/10 (20130101) |
Current International
Class: |
F23G
5/46 (20060101); C01B 3/40 (20060101); C01B
3/22 (20060101); F02C 3/28 (20060101); F02C
3/26 (20060101); C01B 3/00 (20060101); C10J
3/00 (20060101); F23G 5/027 (20060101); F02g
003/00 () |
Field of
Search: |
;60/39.05,39.04,39.12
;210/63 ;48/29UX |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Croyle; Carlton R.
Assistant Examiner: Olsen; Warren
Parent Case Text
CROSS REFERENCES
This application is a Continuation-in-Part of Ser. No. 34,834,
filed May 5, 1970, entitled "Catalytic Hydrogen Manufacture," the
disclosure of which application is incorporated by reference in the
present patent application.
Claims
I claim:
1. The process for gasifying waste material and producing energy
which comprises:
1. forming a combustible synthesis gas by contacting a mixture of
solid organic waste material and 1 to 50 weight percent, based on
the weight of solid organic waste material, of an alkali metal
carbonate catalyst, with steam at an elevated temperature;
2. combusting at least a portion of said gas; and
3. rotating a turbine by expanding said combusted gas through the
turbine; and said organic waste material containing at least 10
weight percent chemically bonded oxygen and containing less than 5
weight percent sulfur.
2. The process in accordance with claim 1 wherein the turbine is
used to drive an electricity generator.
3. The process in accordance with claim 1 wherein the alkali metal
catalyst is potassium carbonate or sodium carbonate.
4. The process in accordance with claim 1 wherein the alkali metal
catalyst is potassium carbonate.
5. The process in accordance with claim 1 wherein the temperature
in the reaction zone is maintained between 700.degree.F. and
2,000.degree.F.
6. The process in accordance with claim 1 wherein the temperature
in the reaction zone is maintained between 1,000.degree.F. and
1,400.degree.F.
7. The process in accordance with claim 1 wherein a gas comprising
oxygen is fed to the reaction zone and a portion of the solid
organic waste feed material to the reaction zone is burned with the
oxygen to provide at least a portion of the endothermic heat of
reaction for the conversion of the organic feed material plus steam
to combustible synthesis gas.
8. The process in accordance with claim 1 wherein the oxygen
content of the solid organic waste feed material is at least 20
weight percent.
9. The process in accordance with claim 1 wherein the oxygen
content in the organic feed material is between 35 and 70 weight
percent.
10. The process for gasifying waste material and producing energy
which comprises forming a combustible synthesis gas by contacting a
mixture of solid organic waste material containing at least 10
weight percent chemically combined oxygen and containing less than
5 weight percent sulfur, and 1 to 50 weight percent of a potassium
carbonate catalyst with steam at a temperature between
1,000.degree.F, and 1,400.degree.F., combusting at least a portion
of the combusting gas to obtain combusted gases, and expanding the
combusted gases through a turbine.
11. The process in accordance with claim 10 wherein the turbine is
used to drive an electrical generator to produce electrical
power.
12. The process in accordance with claim 10 wherein the organic
feed material is solid waste material selected from the group
consisting of solid municipal waste, industrial waste, or
agricultural waste.
13. The process in accordance with claim 1 wherein the solid
organic waste material feedstock is selected from the group
consisting of municipal solid wastes, agricultural wastes and dried
sewage.
14. The process in accordance with claim 1 wherein the solid
organic waste material feedstock is a cellulosic material.
Description
BACKGROUND OF THE INVENTION
The present invention relates to the gasification of carbonaceous
solid waste material containing a minimum amount of combined
oxygen; and the present invention also relates to the generation of
energy by combustion of gases obtained in the gasification of the
waste material and preferably expanding the combusted gases through
a turbine.
Various gasification methods have been suggested for carbonaceous
matter. Among these methods are steam-hydrocarbon reforming,
partial oxidation of hydrocarbons, Lurgi heavy hydrocarbons
gasification, the traditional steam, red-hot coke reaction,
modified methods of reacting carbonaceous matter with steam and
oxygen, such as described in U.S. Pat. No. 1,505,065, coal
gasification and lignite gasification.
The two leading processes, that is, the two processes which are
most frequently used to generate hydrogen, are steam-hydrocarbon
reforming and partial oxidation of hydrocarbons.
In typical steam reforming processes, hydrocarbon feed is
pretreated to remove sulfur compounds which are poisons to the
reforming catalyst. The desulfurized feed is mixed with steam and
then is passed through tubes containing a nickel catalyst. While
passing through the catalyst-filled tubes, most of the hydrocarbons
react with steam to form hydrogen and carbon oxides. The tubes
containing the catalyst are located in a reforming furnace, which
furnace heats the reactants in the tubes to temperatures of
1,200.degree.F. - 1,700.degree.F. Pressures maintained in the
reforming furnace tubes range from atmospheric to 450 psig. If a
secondary reforming furnace or reactor is employed, pressures used
for reforming may be as high as 450 psig to 700 psig. In secondary
reformer reactors, part of the hydrocarbons in the effluent from
the primary reformer is burned with oxygen. Because of the added
expense, secondary reformers are generally not used in pure
hydrogen manufacture, but are used where it is desirable to obtain
a mixture of H.sub.2 and N.sub.2, as seen in ammonia manufacture.
The basic reactions in the steam reforming process are:
C.sub.n H.sub.2n.sub.+2 +nH.sub.2
0.revreaction.nCO+(2n+1)H.sub.2
C.sub.n H.sub.2n.sub.+2 +2nH.sub.2 0.revreaction.nCO.sub.2
+(3n+1)H.sub.2
e.g., methane-steam:
CH.sub.4 +H.sub.2 0.revreaction.CO+3H.sub.2
and,
CH.sub.4 +2H.sub.2 0.revreaction.CO.sub.2 +4H.sub.2
In typical partial oxidation processes, a hydrocarbon is reacted
with oxygen to yield hydrogen and carbon monoxide. Insufficient
oxygen for complete combustion is used. The reaction may be carried
out with gaseous hydrocarbons or liquid or solid hydrocarbons, for
example, with methane, the reaction is:
CH.sub.4 + 1/20.sub.2 .revreaction.2H.sub. 2 +CO
With heavier hydrocarbons, the reaction may be represented as
follows:
C.sub.7 H.sub.12 +2.8 O.sub.2 :2.1 H.sub.2 .revreaction.6.3 CO+0.7
CO.sub.2 +8.1 H.sub.2
Both catalytic and noncatalytic partial oxidation processes are in
use. Suitable operating conditions include temperatures from
2,000.degree.F. up to about 3,200.degree.F. and pressures up to
about 1200 psig, but generally pressures between 100 and 600 psig
are used. Various specific partial oxidation processes are
commercially available, such as the Shell Gasification Process,
Fauser-Montecatini Process, and the Texaco Partial Oxidation
Process.
There is substantial carbon monoxide in the hydrogen-rich gas
generated by either reforming or partial oxidation. To convert the
carbon monoxide to hydrogen and carbon dioxide, one or more CO
shift conversion stages are typically employed. The CO shift
conversion reaction is:
CO+H.sub.2 O.fwdarw.H.sub.2 +CO.sub.2
This reaction is typically effected by passing the carbon monoxide
and H.sub.2 O over a catalyst such as iron oxide activated with
chromium.
Production of hydrogen and other gases from waste substances
produced in the manufacture of paper from wood chips, and the like
has been discussed in the literature as, for example, in U.S. Pat.
No. 3,317,292. In the manufacture of paper, wood chips are
digested, for example, with an aqueous calcium sulfide liquid
thereby forming calcium lignin sulfonate waste product in solution,
leaving wood pulp behind. As disclosed in U.S. Pat. No. 3,317,292,
the waste substances containing lignin-derived organic components
can be converted to a gas mixture comprising hydrogen by contacting
the waste material with steam in a reaction zone at an elevated
temperature at least of the order of several hundred degrees
centigrade. The sulfide waste liquor produced in the manufacture of
paper from wood chips and the like is a relatively well-defined
waste material consisting mostly of lignin-type organic compounds
and certain inorganic components, including at least 5 weight
percent sulfur calculated as the element sulfur but present usually
in the form of sulfur compounds.
The use of catalysts such as potassium carbonate has been disclosed
for the reaction of carbon with steam to form hydrogen as is
discussed, for example, in Journal of the American Chemical
Society, Vol. 43, page 2055 (1921). However, the use of catalysts
such as potassium carbonate to catalyze the reaction of organic
material containing substantial amounts of oxygen, particularly
waste or garbage-type material with steam to form hydrogen does not
appear to be disclosed or suggested in the prior art.
U.S. Pat. No. 3,471,275 discloses a method for converting refuse or
garbage-type material to gases such as gases rich in hydrogen.
According to the process disclosed in U.S. Pat. No. 3,471,275, the
refuse is fed to a retort and heated therein to a temperature
between about 1,650.degree.F. and 2,200.degree.F. The retort is
externally heated. According to the 3,471,275 patent process, steam
is not generally added to the retort. Any steam which is added to
the retort according to the process disclosed in the 3,471,275
patent is added to the bottom of the retort so that steam would
flow counter-current to the waste material which is introduced to
the retort at the top of the retort. No catalyst is used in the
3,471,275 patent process.
As indicated previously, the present invention in addition to
gasification relates to the production of energy by combusting the
gases obtained from gasification and then expanding the gases
through a turbine. Gas turbines are described in Perry's Chemical
Engineer's Handbook, Fourth Edition, at page 24-77 to 24-80. As
indicated in Perry's Handbook, gas turbines can use a wide variety
of fuels. Major fuel limitations are that it does not (1) form
ashes which deposite on the blades and interfere with operation,
(2) contain dust which will erode the blades, and (3) contain
uninhibited vanadium. Gas turbines are now operating on fuel gas
(natural and refinery), blast-furnace gases, fuel oils (including
heavy residuals), and at least one coal-burning gas turbine is
operating.
As described in a report titled: "New Fossil-Fueled Power Plant
Process Based on Lurgi Pressure Gasification of Coal" by Paul F. H.
Rudolph delivered at an ACS meeting on May 27, 1970, coal burning
gas turbines are used at Lunen in West Germany to drive electricity
generators. As disclosed in that report, carbon or coal can be
gasified in the presence of oxygen and H.sub.2 O at a temperature
of 790.degree.C. (1,454.degree.F.). Gases from the gasification
zone, which consist of CO, are purified to remove coal dust and fly
ash and also many other impurities such as vaporized ash, alkali,
and chlorine which are detrimental to the operation of gas
turbines. After purification of the gases from the gasification
step, the gases are then combusted with air and then expanded
through a gas turbine which turbine is used to drive an electricity
generator. The amount of air introduced to the combustor chamber is
adjusted so that the outlet temperature from the combustor and the
inlet temperature to the gas turbine is about 820.degree.C.
(1,508.degree.F.).
The Rudolph report is directed to the gasification of coal and also
mentions that other gasification plants are used to gasify similar
material such as sub-bituminous coal and lignite. The Rudolph
report does not disclose the gasification of high oxygen content
organic waste material in the presence of alkali metal catalysts.
The Rudolph report is hereby incorporated by reference into the
present patent specification.
SUMMARY OF THE INVENTION
According to the present invention, a process is provided for
gasifying waste material and producing energy which process
comprises contacting a solid organic waste material containing at
least 10 weight percent oxygen with steam in the presence of an
alkali metal carbonate catalyst at an elevated temperature to
obtain a gas, combusting at least a portion of said gas to obtain
combusted gases and expanding the combusted gases through a turbine
to rotate the turbine.
An important feature of the present invention is that the invention
provides a process to convert large quantities of waste material,
such as municipal garbage, which currently presents a difficult
disposal problem, to valuable energy, preferably electrical
energy.
I have found that solid organic waste material containing at least
10 weight percent oxygen is converted at an unexpectedly high rate
to combustible gases and that the defined organic feed material is
converted at an unexpectedly high rate to combustible gas when the
conversion is carried out in accordance with the present invention.
We have found that the rate of conversion of the organic feed
material is particularly fast when a potassium carbonate catalyst
is used to accelerate the reaction rate.
The reason for the fast reaction rate for the formation of
combustible gases in the process of the present invention is not
completely understood, but it is believed that an important factor
is the oxygen content of the organic feed material in the process
of the present invention. The organic feed material, which in this
specification is to be understood to contain hydrogen, as well as
carbon, must contain at least 10 weight percent oxygen which can be
contrasted to the essentially nil amount of oxygen present in
hydrocarbon feedstocks to synthesis gas-producing processes such as
steam-light hydrocarbon reforming or hydrocarbon partial oxidation.
The presence of oxygen in the organic feed material in the process
of the present invention may contribute to the relatively fast
reaction rate by making the feed material more susceptible to
reaction with additional steam to produce hydrogen than in the case
of hydrocarbon material containing little or no oxygen. I have
found that it is particularly preferable in the process of the
present invention to produce a synthesis gas from organic feed
material containing at least 20 weight percent oxygen and still
more preferably, between about 35 and 70 weight percent oxygen.
I have also found that organic feed material containing the oxygen
substantially in the form of polyhydroxylated compounds is
particularly advantageous from the standpoint of high reaction
rates with steam to form synthesis gas. Feeds containing oxygen in
the form of polyhydroxylated compounds are meant to include
carbohydrates such as cellulose and sugars.
The oxygen and the hydrogen content in the organic feed material
are to be understood as chemically combined oxygen and hydrogen,
i.e., oxygen and hydrogen which are connected through one or more
chemical bonds to the carbon present in the organic feed material.
Solid waste material which is largely cellulosic, as for example
agricultural waste such as corn husks or solid municipal waste such
as common garbage containing a large amount of paper, are
particularly preferred feedstocks to the process of the present
invention. Usually and preferably, the oxygen in the solid waste
feedstock to the process of the present invention is oxygen which
is directly chemically bonded to carbon in the solid waste
feedstock.
In general, the term "solid organic waste material" is used herein
to connote solid municipal waste or common garbage, sewage,
industrial wastes such as sawdust, and agricultural wastes such as
corn husks and other discarded cellulosic materials.
An important aspect of the present invention is the bringing
together of the two concepts that garbage material or solid
municipal waste can be converted to a combustible gas and that the
combustible gas can be converted to energy, most preferably
electrical energy. In the process of the present invention, the
electrical energy is generated by expanding combusted gases
obtained from the gasification of solid wastes, such as solid
municipal waste in a gas turbine with the gas turbine being used to
drive an electricity generator. This type of plant can be employed
at various locations to solve the increasing problem of solid
municipal waste disposal, particularly the disposal of increasing
amounts of municipal garbage.
Another very important aspect of the present invention which
cooperates in the over-all process of the present invention to make
the process of the present invention more economically feasible is
the discovery of the surprising catalytic effect of alkali metals,
particularly potassium, to accelerate the reaction of oxygen
containing organic material and particularly to accelerate the
gasification of solid municipal waste such as garbage to produce a
combustible gas which can be burned to supply the driving power for
the gas turbine.
It is preferred in the process of the present invention to use an
organic oxygen containing feed material which contains less than 5
weight percent sulfur. The sulfur is calculated as the element
sulfur, although for those undesired and excluded feedstocks, the
sulfur is usually present as a compound as, for example, an organic
sulfur compound or an inorganic sulfur compound present in the feed
material. Thus, it is to be understood that the organic feed
material contacted with steam according to the process of the
present invention is preferably free from a high percentage of
inorganic or organic sulfur compounds, i.e., that the feed contains
less than 5 weight percent sulfur either as sulfur chemically
combined with the organic feed material or as inorganic sulfur
compounds physically mixed with the organic feed material. Feeds
such as Kraft black liquor produced as a waste material in the
manufacture of paper pulp are usually not suitable in the process
of the present invention because of the relatively high content of
sulfur compounds in the Kraft black liquor. It is undesirable to
have substantial amounts of sulfur feed to the reaction zone in the
process of the present invention because of the increased reactor
cost and, more particularly, because of the increased problems in
removing sulfur compounds from the synthesis gas produced in the
reactor. It is preferred that the sulfur content of the organic
feed material be below about 3 weight percent sulfur.
The catalyst used in the process of the present invention is
preferably an alkali metal catalyst, as we have found particularly
high reaction rates using alkali metal catalysts. Potassium
carbonate has been found to be particularly preferable among the
alkali metal catalysts. Other catalysts comprising Group VIII
metals such as nickel can be used in the process of the present
invention, but nickel catalysts have been found to be relatively
susceptible to sulfur poisoning even at relatively low sulfur
contents for the organic feedstock to the process of the present
invention. Nickel catalysts are not soluble in water and thus
cannot be readily recovered from the ash product from the reaction
zone for reuse as a catalyst such as can be done with the alkali
metal catalyst like potassium carbonate. Thus, although we have
recently found that nickel catalysts such as nickel acetate i.e.,
Ni(Ac).sub.2, nickel nitrate i.e., Ni(NO.sub.3).sub.2, result in a
very high reaction rate for combustible gas production from oxygen
containing organic feedstocks at temperatures between about
1,200.degree.F. and 1,400.degree.F, alkali metal catalysts such as
the potassium carbonate catalysts are preferred because of their
very low susceptibility to sulfur poisoning and because of their
recoverability, for example, by removing them from gasification
zone ash by dissolving them in water.
The alkali metal catalysts include lithium, sodium, potassium,
rubidium and cesium. Preferably, the alkali metal is added to the
reaction zone by contacting the feed to the reaction zone with a
solution of a salt of the alkali metal catalyst. The salts of the
alkali metal catalyst include salts such as sulfates and chlorides.
Although it is preferred to add the alkali metal catalyst to the
reaction zone in the form of a carbonate, it is suitable to add the
catalyst in other forms such as hydroxides or acetates, formates,
sulfates, chlorides, or other alkali metal salts. It is believed
these compounds will tend to be converted to carbonates in the
reaction zone.
Preferred amounts of the catalyst as a weight percentage of the
organic feed material are from 1 to 50 weight percent and
particularly preferred amounts are from 5 to 20 weight percent.
When using the particularly preferred potassium carbonate catalyst,
about 2 to 15 weight percent potassium carbonate is preferably
impregnated into the feed before contacting the feed with steam in
the reaction zone.
As indicated previously, the organic feed material to the process
present of the invention must contain a minimum amount of oxygen,
namely at least 10 weight percent oxygen. Particularly preferred
feedstocks contain 20 percent or more combined oxygen. As indicated
in my copending application Ser. No. 34,834, the reason for the
fast reaction rate for the formation of hydrogen-rich gas in the
catalytic reaction according to the process of the present
invention is not completely understood, but the oxygen content of
the feedstock has been found to be a realted factor to the fast
reaction when using the alkali metal catalyst. Furthermore,
progressively higher oxygen contents, particularly from 10 to 25
weight percent, have been found to result in progressively faster
reaction rates for the formation of hydrogen-rich gas in the
process of the present invention.
An important advantage obtained in the process of the present
invention compared to coal gasification processes using no alkali
metal catalyst, is the essentially complete elimination of
chlorides such as hydrogen chloride and many other acid gases
excepting hydrogen sulfide by reaction of the added alkali metal
catalyst used in accordance with the process of the present
invention with acid constituents such as hydrogen chloride formed
in the gasification zone.
In the process of the present invention, it is preferred to add an
oxygen-containing gas such as air or molecular oxygen to the
reaction zone to burn a portion of the organic feed material with
steam to form synthesis gas and carbon oxides. The heat for the
reaction can also be supplied by heating the steam fed to the
reaction zone to a sufficiently high temperature to supply the
required amount of heat for the endothermic reaction of steam plus
organic material to form synthesis gas.
Although the gasification reaction of the present invention can be
carried out at temperatures between about 700.degree. and
2,000.degree.F., it is strongly preferred to use a lower
temperature, preferably between 1,000.degree. and 1,400.degree.F.,
and still more preferaby between 1,100.degree. and 1,300.degree.F.
The lower temperature is particularly made feasible in my process
because of the relatively fast reaction rate obtained with
oxygen-containing waste material using an alkali metal catalyst
such as potassium carbonate. Advantages achieved using the lower
temperature include greater life for the gasification reactor,
better heat efficiency, less tendency to slagging of glass, and
less expensive reactor metallurgy requirements. Therefore, the
lower temperatures used in the process of the present invention
compared to other gasification processes is a very important
advantage.
The concept of the present invention also is extendable to
generating energy, from high oxygen content solid waste material,
in other manners as, for example, by generating a combustible gas
from oxygen-containing solid waste material followed by combusting
the gas in a steam boiler so as to obtain steam which can be used
to drive a turbine, the energy of which turbine can be used to
generate electrical power. Also, particularly since the gases
obtained according to the process of the present invention are rich
in hydrogen (especially at the low temperatures made feasible in
the gasification zone of the present invention), the gases can be
combusted in a fuel cell to convert the gases to electrical
energy.
EXAMPLES
1. Fifty grams of simulated solid municipal waste composed of 50
weight percent paper, 10 weight percent sawdust, 3 weight percent
wool, 2 weight percent plastic, 10 weight percent cotton, 10 weight
percent iron, 2 weight percent aluminum, and 13 weight percent food
peels such as orange peels, etc. The oxygen content of this
particular organic feed material was approximately 50 percent by
weight excluding the metallic materials, i.e., iron and aluminum in
the reactor charge.
Fifty-three millileters of H.sub.2 O was added to the quartz
reactor over a 4-hour period. The internal reaction zone in the
reactor was maintained at a temperature of about 1,200.degree.F. to
1,400.degree.F. during most of the reaction time. No catalyst was
used in this laboratory run.
Over the four-hour period, the total gas production was
approximately 22 liters. The maximum gas production rate during the
four-hour run period was about 10 liters per hour. The gas produced
contained about 60 volume percent hydrogen with the remainder being
mostly CO.sub.2 and CO.
Remaining from the 50 grams charge to the reactor was 11.8 grams of
residue. 6.3 grams of this residue was iron and aluminum. The
carbon, hydrogen, oxygen elemental analysis of the organic residue
was about 85 weight percent C, about 1.4 weight percent H, and
about 14 weight percent 0.
The above results illustrate that solid waste material can be
converted to substantial amounts of combustible gases with the
simultaneous production of a residue which is sanitary because of
the high temperature treatment of the solid waste material and the
breaking down of the solid waste material into various
constituents. The results also illustrate that the combustible gas
can be produced at a fairly high rate; the rate of combustible gas
production from the garbage was surprisingly found to be
considerably higher than the rate of combustible gas production
from carbon by reacting carbon with H.sub.2 O under similar
temperature conditions.
2. In a subsequent run, 50 grams of simulated solid municipal waste
having the same composition as in the preceding example was reacted
with steam in the presence of 16.6 weight percent potassium
carbonate catalyst based on the 50 grams of solid municipal waste
feed. The alkali metal catalyst resulted in a surprising increase
in the hydrogen gas production. Compared to 22 liters of gas
produced over 4 hours in the preceding example with no catalyst,
54.6 liters of gas were produced in this run using the alkali metal
catalyst. Compared to a maximum gas production rate of 10 liters
per hour in the preceding example, the gas production rate in this
run using an alkali metal catalyst was 24 liters per hour.
The composition of the gas produced was approximately as
follows:
C.sub.1 5.2 volume percent C.sub.2 -C.sub.5 2.1 volume percent CO
6.8 volume percent CO.sub.2 21.6 volume percent H.sub.2 64.3 volume
percent
The above gas analysis was based on approximately 18.1 liters of
gas collected while the reaction zone was raised, by electrical
heating of the reactor, from about 800 to 1,200.degree.F. When
heating the solid waste feed from 1,200.degree.F. -
1,400.degree.F., 27.6 liters of gas were recovered having the
composition shown below:
C.sub.1 0.5 volume percent C.sub.2 -C.sub.5 Nil CO 17.2 volume
percent CO.sub.2 18.7 volume percent H.sub.2 63.6 volume
percent
The residue recovered after this run was about 12.4 grams composed
of 5.6 grams iron and iron oxide, 0.8 grams aluminum and aluminum
oxide, 5.0 grams potassium carbonate, and 1.0 grams water-insoluble
ash.
3. Another run was carried out using 50 grams of simulated solid
municipal waste having the same composition as in the preceding
examples, but using 10 weight percent sodium carbonate catalyst.
The sodium carbonate catalyst was found to be very effective in
increasing the rate of hydrogen production. The maximum rate of
combustible gas production during this run was 34 liters per hour
compared to only 10 liters per hour in the Example 1 above, wherein
no catalyst was used. The total amount of combustible gas produced
in this run was 47.1 liters.
The temperature range during this run was essentially the same as
that in the preceding examples with the maximum temperature being
1,425.degree.F.
The residue recovered after the run was about 12.2 grams composed
of 5.4 grams iron and iron oxide, 0.8 grams aluminum and aluminum
oxide, 1.5 grams water insoluble ash, and 3.2 grams sodium
carbonate.
The amount of H.sub.2 O added during this run was about 16
milliliters per hour, compared to 14 milliliters per hour for the
previous example wherein the potassium carbonate catalyst was
used.
4. Fifty grams of dried Milwaukee sewage, commonly referred to as
Milorganite, was impregnated with about 10 weight percent sodium
carbonate and then reacted with steam at a temperature within the
range of about 1,200.degree.F. - 1,440.degree.F. The reaction was
carried out over a period of about 6 hours and 39 liters of gas
were produced. The gas contained about 63 volume percent hydrogen
and about 11 percent CO. 12.3 grams of residue remained. About 2.5
grams of the residue was soluble in water and could be processed to
recover a large amount of the sodium carbonate catalyst for re-use
in the catalytic reaction. 5. If the gas produced in Example 2 were
converted to kilowatt hours, a theoretical field of approximately
0.13 KWH can be produced from 50 gr. of organic feed. This is equal
to 1,000 KWH/ton of organic feed, assuming a turbine efficiency of
42 percent.
Although various embodiments of the invention have been described,
it is to be understood that they are meant to be illustrative only
and not limiting. Certain features may be changed without departing
from the spirit or scope of the invention. It is apparent that the
present invention has broad application to gasification of solid
waste containing at least 10 weight percent chemically combined
oxygen to obtain a combustible gas, followed by combusting the
combustible gas and expanding the combusted gas through a gas
turbine in order to obtain energy. The invention is not to be
construed as limited to the specific embodiments or examples
discussed but only as defined in the appended claims or substantial
equivalents thereto.
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