Coke slurry fuel composition and method of making the same

Abstract

A coke slurry fuel composition of the instant disclosure comprises 40-80 percentage by weight of petroleum coke (dry basis), 20-60 percentage by weight of biological sludge (wet basis), and 1-4 percentage by weight of basic additive. Accordingly, the coke slurry fuel composition with high combustion efficiency can be adapted to reduce emissions of toxic or air pollutants, and the purpose of sludge reduction can also be achieved. A method of making coke slurry fuel composition is further provided.

What is claimed is: 
     
         1 . A coke slurry fuel composition, having a burnout rate of at least 97%, comprising (a) petroleum coke, (b) biological sludge, and (c) a basic additive;
 wherein the content of the component (a) is 40 wt % to 80 wt % on a dry basis, the content of the component (b) is 20 wt % to 60 wt % on a wet basis, and the content of the component (c) based on the entire amount of components (a) and (b) is 1 wt % to 4 wt %;   wherein the component (c) is added to control the sulfur-oxygen compounds (SOx) generated by the burning of the coke slurry fuel composition, whereby the content of SOx in the fuel gas is less than about 150 ppm.   
     
     
         2 . The coke slurry fuel composition according to  claim 1 , wherein the component (b) is derived from domestic sewage, industrial sewage, animal sewage, municipal sewage, or the combination thereof. 
     
     
         3 . The coke slurry fuel composition according to  claim 1 , wherein the component (c) is selected from the group consisting of sodium carbonate, sodium hydroxide, sodium silicate, sodium tripolyphosphate, and the combination thereof. 
     
     
         4 . The coke slurry fuel composition according to  claim 3 , having a water content in the range of 35% to 42% and a viscosity less than 1250 mPa*s at 20° C. 
     
     
         5 . The coke slurry fuel composition according to  claim 4 , the nitrogen-oxygen compounds (NOx) generated by the burning of which is less than about 30 ppm. 
     
     
         6 . The coke slurry fuel composition according to  claim 5 , further comprising (d) gutter oil and (e) activated carbon waste or reactive coke, the content of the component (d) based on the entire amount of components (a) and (b) is 5 wt % to 20 wt %, and the content of the component (e) based on the entire amount of components (a) and (b) is 1 wt % to 20 wt %. 
     
     
         7 . A method of making coke slurry fuel composition, comprising the following steps:
 providing petroleum coke pellets and biological sludges;   feeding a cluster of petroleum coke pellets into a slurry of biological sludge in a predetermined ratio according to a desired calorific value to form a fuel precursor, and then agitating and grinding the fuel precursor simultaneously to form a petroleum coke-based fuel slurry; and   screening the petroleum coke-based fuel slurry.   
     
     
         8 . The method according to  claim 7 , wherein the fuel precursor is agitated and ground adequately by wet ball-milling in the present of a processing aid in an amount in the range of 1% to 5% and a basic additive in an amount in the range of 0.5% to 2.5% in the step of feeding a cluster of petroleum coke pellets into a slurry of biological sludge. 
     
     
         9 . The method according to  claim 8 , wherein the processing aid is selected from the group consisting of ligninsulfonate, naphthalene sulfonic acid, sodium polyacrylate acid, poly(styrenesulfonic acid), carboxymethyl cellulose, and the combination thereof, and the basic additive is selected from the group consisting of sodium carbonate, sodium hydroxide, sodium silicate, sodium tripolyphosphate, and the combination thereof. 
     
     
         10 . A method of making coke slurry fuel composition, comprising the following steps:
 providing petroleum coke pellets and biological sludges;   dry-grinding the petroleum coke pellets to form petroleum coke particles and wet-grinding the biological sludge to form a microalgal slurry, and then screening the petroleum coke particles;   feeding a cluster of the screened petroleum coke particles into the microalgal slurry in a predetermined ratio according to a desired calorific value, mixing adequately, to form a petroleum coke-based fuel slurry; and   screening the petroleum coke-based fuel slurry.   
     
     
         11 . The method according to  claim 10 , wherein the biological sludges are adequately ground by wet ball-milling to rupture the microalgae cells and form the microalgal slurry in the presence of a basic additive in an amount in the range of 0.5% to 2.5% in the step of wet-grinding the biological sludge to a desired size. 
     
     
         12 . The method according to  claim 11 , wherein the screened petroleum coke particles is mixed adequately with the microalgal slurry in the presence of a processing aid in an amount in the range of 1% to 4% in the step of feeding a cluster of the screened petroleum coke particles into the microalgal slurry. 
     
     
         13 . The method according to  claim 12 , wherein the processing aid is selected from the group consisting of ligninsulfonate, naphthalene sulfonic acid, sodium polyacrylate acid, poly(styrenesulfonic acid), carboxymethyl cellulose, and the combination thereof, and the basic additive is selected from the group consisting of sodium carbonate, sodium hydroxide, sodium silicate, sodium tripolyphosphate, and the combination thereof. 
     
     
         14 . A method of making coke slurry fuel composition, comprising the following steps:
 providing petroleum coke pellets and biological sludges;   wet-grinding the petroleum coke pellets and the biological sludges respectively to form a petroleum coke slurry and a microalgal slurry, and screening the petroleum coke slurry and the microalgal slurry; and   feeding the screened petroleum coke slurry and the screened microalgal slurry in a predetermined ratio according to a desired calorific value, mixing adequately, to form a petroleum coke-based fuel slurry.   
     
     
         15 . The method according to  claim 14 , wherein the petroleum coke pellets are adequately ground to a desired size, and the biological sludges are adequately ground to rupture the microalgae cells and form the microalgal slurry in the presence of a processing aid in an amount in the range of 1% to 4% in the step of wet-grinding the petroleum coke pellets and the biological sludges respectively. 
     
     
         16 . The method according to  claim 15 , wherein the screened petroleum coke slurry are mixed with the screened microalgal slurry adequately in the presence of a basic additive in an amount in the range of 0.5% to 2.5% in the step of feeding the screened petroleum coke slurry and the screened microalgal slurry. 
     
     
         17 . The method according to  claim 16 , wherein the screened petroleum coke particles are mixed adequately with the microalgal slurry in the presence of a processing aid in an amount in the range of 1% to 5% in the step of feeding a cluster of the screened petroleum coke particles into the microalgal slurry.