Fuel and related compositions – Liquid fuels – Emulsion fuel
Reexamination Certificate
2000-12-12
2004-06-22
Toomer, Cephia D. (Department: 1714)
Fuel and related compositions
Liquid fuels
Emulsion fuel
C044S280000, C044S628000
Reexamination Certificate
active
06752843
ABSTRACT:
FIELD OF THE INVENTION
The field of the present invention is directed to a process for producing and applying an asphalt emulsion and, particularly, to a process for producing an oil-in-water asphalt emulsion, creating an aerosol from the asphalt emulsion using an atomizer and injecting the aerosol into an agitated coal stream.
BACKGROUND OF THE INVENTION
Developing efficient means for producing alternative fuel sources is important in societies dependent on fuel. The process for developing synthetic fuel (“synfuel”) from coal is one such alternative. The synfuel process converts coal fines into a synthetic fuel through a chemical reaction with a petroleum-derived asphaltic binder. Asphaltic binders contain molecules with chemically reactive functional groups that can react with the feedstock coal fines to produce a synthetic fuel. As a result of these chemical reactions, such a synthetic fuel has a chemical composition that is significantly different from that of the feedstock.
According to one such synfuel process, the asphaltic binder is applied directly to the coal fines in a high-speed blender. This technology is effective in producing chemical change, but requires relatively high amounts of binder. Also, disadvantageously, the viscous melted asphalt is difficult to spread evenly onto coal fines and requires extensive mixing time.
According to another synfuel process, the asphaltic binder is applied in the form of an asphalt emulsion. The asphalt emulsion and the coal fines are mixed with to produce a rather gummy mixture. The asphalt emulsion generally comprises at least asphalt and water and may further include additives, such as various polymers to improve downstream processing. The resulting mixture of coal and asphalt emulsion is further processed. Pressure is applied to the mixture to expel the majority of the water, thus allowing the asphalt to more fully react with the carbon chain in the coal. Such asphalt emulsion processes involve the production of the asphalt emulsion at a central location and require that the resultant asphalt emulsion be shipped long distances. Accordingly, the asphalt emulsion must be relatively stable over a period of time. This often requires high levels of additives, such as soap or other stabilizers, to prevent premature breaking of the emulsion. An emulsion breaks when it spontaneously separates back into an oil phase and a water phase.
Hence, there exists a need for an improved asphalt emulsion-based synthetic fuel process, which overcomes the disadvantages of the existing processes.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved process for introducing an asphalt into a synthetic fuel process.
A further object of the present invention is to provide an improved process for introducing an asphalt into a synthetic fuel process that allows for the debottlenecking of the synthetic fuel process.
A still further object of the present invention is to provide an improved process for introducing an asphalt into asynthetic fuel process that provides for higher throughput while still achieving the requisite chemical change necessary in a synthetic fuel process.
Another object of the present invention is to provide an improved process for producing an asphalt emulsion spray.
Yet another object of the present invention is to provide a more cost-effective way of producing an asphalt emulsion.
In order to achieve these and other objects, there is provided, in accordance with one aspect of the present invention, a process for introducing an asphalt into a synthetic fuel process, comprising the steps of introducing into the process an oil-in-water asphalt emulsion; passing the asphalt emulsion to an atomizer, adding to the atomizer a motivating gas to form an asphalt aerosol spray; agitating a coal fines feed stream; and injecting the aerosol spray into the agitated coal fines. The asphalt emulsion preferably comprises asphalt particles having an average diameter of about 5 microns or less. The asphalt emulsion can be anionic, cationic or non-ionic, more preferable anionic. The emulsion preferably has a pH of about 7.0 or greater. The asphalt preferably comprises no greater than about 50% by volume of the asphalt emulsion, more preferably about 30 to 50% by volume of the asphalt emulsion.
The introducing step preferably comprises manufacturing the asphalt emulsion upstream of the atomizer as part of a continuous, integral process for introducing an asphalt into a synthetic fuel process. The manufacturing step preferably comprises the further steps of introducing into the process an asphalt; creating a mixture of water and soap; mixing in a mixer the asphalt and the water and soap mixture to create an asphalt-soapy water mixture by passing the asphalt and the water and soap mixture along a common directional vector into a high turbulence mixing zone; and emulsifying the asphalt-soapy water mixture to create the asphalt emulsion. The asphalt preferably comprises no greater than about 50% by volume of the asphalt emulsion, more preferably about 30 to 50% by volume of the asphalt emulsion.
The aerosol of the spray preferably has a particle size of about 100 microns to about 500 microns. The atomizer preferably injects the aerosol spray as a flat spray. The gas is preferably selected from the group consisting of air, carbon dioxide, nitrogen and mixtures thereof. The agitated coal fines are preferably mechanically agitated. The mechanical agitating preferably involves continuously folding the coal fines. The aerosol spray preferably is generally evenly distributed over the coal fines.
In accordance with yet another aspect of the present invention, there is provided a process for spraying an asphalt emulsion onto coal in the manufacture of synthetic fuel, comprising the steps of introducing a motivating gas into an atomizer; introducing an oil-in-water asphalt emulsion into the atomizer; creating in the atomizer an atomized stream of emulsion and gas; and spraying the atomized stream onto an agitated coal fines stream. The asphalt emulsion preferably comprises asphalt particles having an average diameter of about 5 microns or less. The emulsion can be anionic, cationic or non-ionic, more preferably is anionic. The emulsion preferably has a pH of about 7.0 or greater. The asphalt preferably comprises no greater than about 50% by volume of the asphalt emulsion, more preferably about 30 to 50% by volume of the asphalt emulsion. The introducing step preferably comprises manufacturing the asphalt emulsion upstream of the atomizer as part of a continuous, integral process for introducing an asphalt into a synthetic fuel process. The manufacturing step preferably comprises the further steps of introducing into the process an asphalt; creating a mixture of water and soap; mixing in a mixer the asphalt and the water and soap mixture to create an asphalt-soapy water mixture by passing the asphalt and the water and soap mixture along a common directional vector into a high turbulence mixing zone; and emulsifying the asphalt-soapy water mixture to create the asphalt emulsion. The gas preferably is selected from the group consisting of air, carbon dioxide, nitrogen and mixtures thereof. The aerosol of the spray preferably has a particle size of about 100 microns to about 500 microns. The aerosol spray preferably is formed by mixing the asphalt emulsion and the motivating gas inside the atomizer. The atomizer preferably injects the aerosol spray as a flat spray. The agitating step preferably comprises mechanically agitating the coal fines. The mechanical agitating preferably involves continuously folding the coal fines.
In accordance with still another aspect of the present invention, there is provided a process for spraying an asphalt emulsion onto coal in the manufacture of synthetic fuel, comprising the steps of introducing into the process an asphalt binder; creating a mixture of water and soap; mixing the asphalt binder and the water and soap mixture to create an asphalt-soapy water mixture; passing the asphalt-soapy water mix
Paspek Stephen C.
Thomas Randy B.
Fulbright & Jaworski L.L.P.
Kentucky Energy, L.L.C.
Toomer Cephia D.
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