Corrosion-resisant surfaces for reactors

Patent metadata

Field	Value
Publication number	US-2016160137-A1
Application number	US-201314906530-A
Country	US
Kind code	A1
Filing date	Aug 1, 2013
Priority date	Aug 1, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

Provided herein are corrosion-resistant reactors that can be used for gasification, and methods of making and using the same. Some embodiments include a corrosion-resistant ceramic layer. According to some embodiments, the corrosion-resistant ceramic layer has a negative charge. At temperature above water's critical point (for example, 374CC and at 22.1 MPa I 218 atm), water can behave as an adjustable solvent and can have tunable properties depending on temperature and pressure.

First claim

1 . A reactor comprising:
a reaction chamber; a metal surface at least partially enclosing the reaction chamber; and a corrosion-resistant ceramic layer disposed between at least a portion of the metal surface and the reaction chamber, the corrosion-resistant ceramic layer having a first surface facing the reaction chamber and a second surface facing the metal surface, wherein the corrosion-resistant ceramic layer is negatively charged and exhibits a negative charge at the first surface that is greater than a negative charge at the second surface.

2 . The reactor of claim 1 , wherein the reactor is configured for supercritical gasification of organic materials.

3 . The reactor of claim 1 , wherein the corrosion-resistant ceramic layer comprises an aluminosilicate material.

4 . The reactor of claim 1 , wherein the corrosion-resistant ceramic layer comprises at least one of a zeolite or a montmorillonite.

5 . (canceled)

6 . The reactor of claim 1 , wherein the corrosion-resistant ceramic layer has a graded negative potential that increases along a thickness of the corrosion-resistant ceramic layer from the second surface the first surface.

7 . The reactor of claim 1 , wherein the corrosion-resistant ceramic layer is nonporous.

8 . The reactor of claim 1 , wherein the corrosion-resistant ceramic layer is porous.

9 . The reactor of claim 1 , wherein the reactor is configured to withstand a temperature greater than or equal to about a supercritical temperature of water, and the reactor is configured to withstand a pressure greater than or equal to about a supercritical pressure of water.

10 . The reactor of claim 1 , wherein the metal surface comprises at least one of stainless steel, a superalloy of nickel, or a superalloy of chromium.

11 . The reactor of claim 1 , further comprising water disposed in the reaction chamber, and an organic material disposed in the reaction chamber.

12 . The reactor of claim 11 , wherein the organic material is coal.

13 . The reactor of claim 1 , wherein the corrosion-resistant ceramic layer has a thickness of about 1 μm to about 10,000 μm.

14 . The reactor of claim 1 , further comprising at least one heating element thermally coupled to the reaction chamber and configured to heat water above a supercritical temperature of water.

15 . The reactor of claim 1 , further comprising at least one inlet port fluidly coupled to the reaction chamber, wherein the inlet port is configured to provide at least one of water or an organic material to the reaction chamber.

16 . The reactor of claim 1 , further comprising at least one outlet port fluidly coupled to the reaction chamber, wherein the outlet port is configured to receive a gas from the reaction chamber.

17 . A method of gasifying an organic material, the method comprising:
providing a reactor comprising:
a reaction chamber;
a metal surface at least partially enclosing the reaction chamber; and
a corrosion-resistant ceramic layer disposed between at least a portion of the metal surface and the reaction chamber, the corrosion-resistant ceramic layer having a first surface facing the reaction chamber and a second surface facing the metal surface, wherein the corrosion-resistant ceramic layer is negatively charged and exhibits a negative charge at the first surface that is greater than a negative charge at the second surface;
disposing the organic material in the reaction chamber; contacting water with the organic material in the reaction chamber, wherein the water is at least at a supercritical temperature and a supercritical pressure; and recovering a gas product from the reaction chamber.

18 . The method of claim 17 , wherein the water is at a temperature of at least about 374° C.

19 . The method of claim 17 , wherein the water is at a pressure of at least about 218 atm.

20 . The method of claim 17 , wherein the gas product comprises a hydrocarbon gas.

21 . The method of claim 17 , wherein the organic material comprises coal.

22 . The method of claim 17 , wherein the corrosion-resistant ceramic layer comprises an aluminosilicate material.

23 . (canceled)

24 . The method of claim 17 , wherein the corrosion-resistant ceramic layer has a graded negative potential that increases along a thickness of the corrosion-resistant ceramic layer from the second surface to the first surface.

25 . A method of making a reaction chamber, the method comprising:
providing a liquid mixture having one or more electrodes at least partially disposed in the liquid mixture, wherein the liquid mixture comprises a ceramic powder dispersed in a solvent; disposing a metal surface at least partially within the liquid mixture; applying a voltage between the electrodes and the metal surface to form a first corrosion-resistant ceramic layer on the metal surface, wherein the first corrosion-resistant ceramic layer is negatively charged and at least partially forms a corrosion-resistant ceramic layer; and forming the reaction chamber using at least the metal surface, wherein the corrosion-resistant ceramic layer is disposed between at least a portion of the metal surface and the reaction chamber; wherein the corrosion-resistant ceramic layer exhibits a first surface facing the reaction chamber and a second surface facing the metal surface, the corrosion-resistant ceramic layer exhibits a negative charge at the first surface that is greater than the negative charge at the second surface.

26 . The method of claim 25 , wherein the ceramic powder comprises a zeolite or a montmorillonite.

27 . The method of claim 25 , wherein the ceramic powder comprises an aluminosilicate.

28 . The method of claim 25 , wherein the ceramic powder comprises a zeolite and a montmorillonite.

29 . The method of claim 25 , wherein the metal surface comprises at least one of stainless steel, a superalloy of nickel, or a superalloy of chromium.

30 . The method of claim 25 , wherein the voltage applied is about 100 V to about 1000 V.

31 . The method of claim 25 , wherein the solvent is one or more of acetone, fluoroether and hydrofluoroether.

32 . The method of claim 25 , further comprising:
disposing the metal surface in a second liquid mixture having one or more second electrodes at least partially disposed in the liquid mixture, wherein the second liquid mixture comprises a second ceramic powder dispersed in a second solvent, and wherein an amount of aluminium in the second liquid mixture is greater than an amount of aluminium in the liquid mixture; and applying a second voltage between the second electrodes and the metal surface to form a second corrosion-resistant ceramic layer on the first corrosion-resistant ceramic layer, the first and second corrosion-resistant ceramic layers at least partially forming the corrosion-resistant ceramic layer, wherein the second corrosion-resistant ceramic layer has a greater negative charge than the first corrosion-resistant ceramic layer.

33 . The method of claim 32 , further comprising:
disposing the metal surface in a third liquid mixture having one or more third electrodes at least partially disposed in the liquid mixture, wherein the third liquid mixture comprises a third ceramic powder dispersed in a third solvent, and wherein an amount

Assignees

• Empire Technology Dev Llc

Inventors

• Seike Aya

Classifications

• C10J3/78 Primary

  High-pressure apparatus · CPC title

• B01J19/02 Primary

  Apparatus characterised by being constructed of material selected for its chemically-resistant properties · CPC title

• C10J3/20

  Apparatus; Plants · CPC title

• C10J2300/0979

  as supercritical steam · CPC title

• B01J8/0005

  Catalytic processes under superatmospheric pressure (non-catalytic processes B01J3/00) · CPC title