Carbonaceous bricks for use in carbon beds of gasification reactors and methods of making carbonaceous bricks

Abstract

A process for forming a carbonaceous article for use among particles in a carbonaceous bed of a thermal reactor, includes forming bricks having a material composition including carbon containing particles other than coke, and at least one of Portland cement, potassium silicate cement, and aluminum silicate cement, in an approximate weight % other than water of: 40 to 95 parts of the carbon containing particles, 0 to 20 parts of the Portland cement, 0 to 20 parts of the potassium silicate cement, and 0 to 20 parts of the aluminum silicate cement.

What is claimed is: 
     
         1 . A process for forming a carbonaceous article for use among particles in a carbonaceous bed of a thermal reactor, the process comprising:
 forming bricks having a material composition including carbon containing particles other than coke, and at least one of Portland cement, potassium silicate cement, and aluminum silicate cement, in an approximate weight % other than water of:   40 to 95 parts of the carbon containing particles,   0 to 20 parts of the Portland cement,   0 to 20 parts of the potassium silicate cement, and   0 to 20 parts of the aluminum silicate cement.   
     
     
         2 . The process of  claim 1 , further comprising:
 mixing the material composition with an amount of water to form a moldable mixture;   pouring the moldable mixture into the molds of a predetermined size and shape for use in a carbonaceous bed; and   allowing the moldable mixture, in the molds, to set and air dry.   
     
     
         3 . The process of  claim 2 , wherein the water is about 15% to 25% of the weight of the moldable mixture. 
     
     
         4 . The process of  claim 2 , further including formation of the carbonaceous bed by including the steps of:
 removing the molded units from the molds, which are shaped to provide the units with average dimensions of about 10 cm to 25 cm across, and   introducing a quantity of the molded units into a reactor vessel to form the carbonaceous bed in which at least about 25% of the carbonaceous bed carbon content is carbon of the molded units.   
     
     
         5 . The process of  claim 1 , wherein the carbon containing particles comprise wood, and the brick further comprise:
 silica and calcium bentonite.   
     
     
         6 . The process of  claim 1 , wherein the carbon containing particles comprise:
 spent potliner.   
     
     
         7 . The process of  claim 1 , wherein the carbon containing particles comprise:
 soot water residue.   
     
     
         8 . The process of  claim 1 , wherein the carbon containing particles comprise:
 plastic.   
     
     
         9 . The process of  claim 1 , wherein the carbon containing particles comprise:
 fly ash.   
     
     
         10 . The process of  claim 1 , wherein the bricks further comprise at least one of:
 silica; calcium carbonate; kaolin clay; sodium bentonite; calcium bentonite; potassium bentonite; sodium silicate; aluminum hydroxide; nickel; and iron.   
     
     
         11 . The process of  claim 1 , further comprising:
 mixing the material composition with an amount of water to form a moldable mixture;   pouring the moldable mixture into the molds of a predetermined size and shape for use in a carbonaceous bed; and   applying either or both heat and pressure to the moldable mixture in the molds.   
     
     
         12 . A carbonaceous article comprising:
 bricks having a material composition including carbon containing particles other than coke, and at least one of Portland cement, potassium silicate cement, and aluminum silicate cement, in an approximate weight % other than water of:   40 to 95 parts of the carbon containing particles,   0 to 20 parts of the Portland cement,   0 to 20 parts of the potassium silicate cement, and   0 to 20 parts of the aluminum silicate cement.   
     
     
         13 . The carbonaceous article of  claim 12 , wherein the carbon containing particles comprise wood, and the carbonaceous article further comprises:
 silica and calcium bentonite.   
     
     
         14 . The carbonaceous article of  claim 12 , wherein the carbon containing particles comprise:
 spent potliner.   
     
     
         15 . The carbonaceous article of  claim 12 , wherein the carbon containing particles comprise:
 soot water residue.   
     
     
         16 . The carbonaceous article of  claim 12 , wherein the carbon containing particles comprise one of:
 plastic or fly ash.   
     
     
         17 . The carbonaceous article of  claim 12 , wherein the bricks further comprise at least one of:
 silica; calcium carbonate; kaolin clay; sodium bentonite; calcium bentonite; potassium bentonite; sodium silicate; aluminum hydroxide; nickel; and iron.   
     
     
         18 . The carbonaceous article of  claim 12 , wherein the bricks have an average dimension of about 10 cm to 25 cm across. 
     
     
         19 . The carbonaceous article of  claim 12 , wherein the bricks include at least about 50% by weight carbon. 
     
     
         20 . The carbonaceous article of  claim 12 , wherein:
 the carbon containing particles comprise one or both of a non-reacted byproduct of a pyrolytic process using carbon either in the presence of or the absence of a plasma, and a non-reacted byproduct of a combustion process using carbon.