Catalytic Gasification of Coal Using Eutectic Salts: Recovery, Regeneration, and Recycle of Spent Eutectic Catalysts

Abstract

Catalyst recovery studies were conducted for gasified chars produced from steam gasification of Illinois #6 coal catalyzed with two different catalyst systems. A ternary (43.5 mol% Li₂ CO₃ –31.5 mol% Na₂ CO₃ –25 mol% K₂ CO₃ ) and a binary (29 mol% Na₂ CO₃ –71 mol% K₂ CO₃ ) eutectic catalyst system were used for gasifying coal. Various extraction schemes, such as water extraction, H₂ SO₄ extraction, and acetic acid extraction, were evaluated with respect to their extraction efficiencies. Effects of major process variables, such as solvent-to-char ratio, mixing time, temperature, and concentration, on the extraction efficiency were evaluated. A process schematic for the entire catalyst recovery, regeneration, and recycle scheme was developed and the preliminary process economics were determined based on these extraction schemes. H₂ SO₄ extraction was found to be the most desirable. It also turned out to be more attractive than a once-through throwaway system.