Abstract: A system for recovering rare earth elements from coal ash includes a leaching reactor, an ash dryer downstream of the leaching reactor, and a roaster downstream of the ash dryer that is cooperatively connected to both the leaching reactor and the ash dryer. Coal ash is mixed with an acid stream such that rare earth elements present in the coal ash are dissolved in the acid stream, thereby creating (i) a leachate containing the rare earth elements and (ii) leached ash. The leachate is heated to obtain acid vapor and an acid-soluble rare earth concentrate. Mixing of the coal ash with the acid stream can occur in a leaching reactor and heating of the leachate can occur in a roaster. The acid-soluble rare earth concentrate can be fed to a hydrometallurgical process to separate and purify the rare earth elements.

Abstract: Methods of recovering rare earth elements, vanadium, cobalt, or lithium from coal are described. The coal is dissolved in a first solvent to dissolve organic material in the coal and create a slurry containing coal ash enriched with rare earth elements, vanadium, cobalt, or lithium. The enriched coal ash is separated from the first solvent. Residual organic material is removed from the coal ash. The rare earth elements, vanadium, cobalt, or lithium can then be recovered from the coal ash. The coal ash is mixed with an acid stream that dissolves the rare earth elements, thereby creating (i) a leachate containing the rare earth elements and (ii) leached ash. The leachate is heated to obtain acid vapor and an acid-soluble rare earth concentrate. The acid-soluble rare earth concentrate can be fed to a hydrometallurgical process to separate and purify the rare earth elements.

Abstract: A method of making a zeolite comprises: adding a zeolite seed to a leach solution containing silicon and aluminum; and heating the leach solution to obtain the zeolite. The leach solution can be made by mixing coal ash with a basic stream, thereby creating (i) a leach solution containing silicon and aluminum, and (ii) leached ash; and separating the leach solution from the leached ash.

Abstract: A system for recovering rare earth elements from coal ash includes a leaching reactor, an ash dryer downstream of the leaching reactor, and a roaster downstream of the ash dryer that is cooperatively connected to both the leaching reactor and the ash dryer. Coal ash is mixed with an acid stream such that rare earth elements present in the coal ash are dissolved in the acid stream, thereby creating (i) a leachate containing the rare earth elements and (ii) leached ash. The leachate is heated to obtain acid vapor and an acid-soluble rare earth concentrate. Mixing of the coal ash with the acid stream can occur in a leaching reactor and heating of the leachate can occur in a roaster. The acid-soluble rare earth concentrate can be fed to a hydrometallurgical process to separate and purify the rare earth elements.

Abstract: Methods of recovering rare earth elements, vanadium, cobalt, or lithium from coal are described. The coal is dissolved in a first solvent to dissolve organic material in the coal and create a slurry containing coal ash enriched with rare earth elements, vanadium, cobalt, or lithium. The enriched coal ash is separated from the first solvent. Residual organic material is removed from the coal ash. The rare earth elements, vanadium, cobalt, or lithium can then be recovered from the coal ash. The coal ash is mixed with an acid stream that dissolves the rare earth elements, thereby creating (i) a leachate containing the rare earth elements and (ii) leached ash. The leachate is heated to obtain acid vapor and an acid-soluble rare earth concentrate. The acid-soluble rare earth concentrate can be fed to a hydrometallurgical process to separate and purify the rare earth elements.

Abstract: A system for recovering rare earth elements from coal ash includes a leaching reactor, an ash dryer downstream of the leaching reactor, and a roaster downstream of the ash dryer that is cooperatively connected to both the leaching reactor and the ash dryer. Coal ash is mixed with an acid stream such that rare earth elements present in the coal ash are dissolved in the acid stream, thereby creating (i) a leachate containing the rare earth elements and (ii) leached ash. The leachate is heated to obtain acid vapor and an acid-soluble rare earth concentrate. Mixing of the coal ash with the acid stream can occur in a leaching reactor and heating of the leachate can occur in a roaster. The acid-soluble rare earth concentrate can be fed to a hydrometallurgical process to separate and purify the rare earth elements.

Abstract: A method of making a zeolite comprises: adding a zeolite seed to a leach solution containing silicon and aluminum; and heating the leach solution to obtain the zeolite. The leach solution can be made by mixing coal ash with a basic stream, thereby creating (i) a leach solution containing silicon and aluminum, and (ii) leached ash; and separating the leach solution from the leached ash.

Abstract: The invention providing methods of loading and unloading particulate from microchannels in apparatus that contains multiple microchannels, typically apparatus that is designed to operate with hundreds or thousands of particulate-containing microchannels. Aligning a sonicating head at one end of a set of microchannels provides a particularly effective mode for densifying particulate in microchannels.

Abstract: Multifunctional catalysts are used to prepare modified bio-oils with improved characteristics. Bio-oil vapor phase, e.g., produced by pyrolysis of biomass, is contacted with a multifunctional catalyst. The multifunctional catalyst catalyzes a plurality of distinct reactions of the bio-oil vapor phase to produce a modified bio-oil.

Abstract: A system for recovering rare earth elements from coal ash includes a leaching reactor, an ash dryer downstream of the leaching reactor, and a roaster downstream of the ash dryer that is cooperatively connected to both the leaching reactor and the ash dryer. Coal ash is mixed with an acid stream such that rare earth elements present in the coal ash are dissolved in the acid stream, thereby creating (i) a leachate containing the rare earth elements and (ii) leached ash. The leachate is heated to obtain acid vapor and an acid-soluble rare earth concentrate. Mixing of the coal ash with the acid stream can occur in a leaching reactor and heating of the leachate can occur in a roaster. The acid-soluble rare earth concentrate can be fed to a hydrometallurgical process to separate and purify the rare earth elements.

Abstract: A dual bed pyrolysis system may include a falling bed reactor employing a heat carrier particulate to pyrolyze biomass to create a pyrolysis product and a pyrolysis waste product. The dual bed pyrolysis system may also include a fluidized bed reactor. The fluidized bed reactor may accept the pyrolysis waste product including char and heat carrier particulate from the falling bed reactor. The fluidized bed reactor may combust the char in the presence of the heat carrier particulate. The fluidized bed reactor may combust the char to reheat the heat carrier particulate. The reheated heat carrier particulate may be provided to the falling bed reactor to pyrolyze biomass to create a pyrolysis product and a pyrolysis waste product.

Abstract: Described are methods and systems for preparing stabilized bio-oil suitable for subsequent hydrotreatment and forming a hydrocarbon product from a stabilized bio-oil. For example, preparing stabilized bio-oil suitable for subsequent hydrotreatment may include filtering bio-oil effective to remove at least a portion of particles having an effective particulate diameter greater than about 10 micrometers; treating the bio-oil effective to remove at least a portion of inorganic species from the bio-oil; and catalytically stabilizing the bio-oil to provide the stabilized bio-oil suitable for subsequent hydrotreatment. Forming a hydrocarbon product from a stabilized bio-oil may include hydrotreating the stabilized bio-oil by, for example, contacting the stabilized bio-oil to a hydrotreatment catalyst in the presence of hydrogen, thereby providing the hydrocarbon product. Also included are stabilized bio-oil and hydrocarbon products derived therefrom.

Abstract: Systems, methods, and apparatuses are provided for upgrading a bio-oil by reaction with an olefin in the presence of a catalyst. For example, upgraded bio-oil may have improved miscibility with hydrophobic fuels.

Abstract: Vapor phase catalytic reactors and methods for using the same for upgrade of fuels produced by fast pyrolysis of biomass are disclosed.

Abstract: Novel methods of electroless plating are described. Catalyst coatings can be applied within microchannel apparatus. Various reactions, including combustion and steam reforming, can be conducted over electroless catalyst coatings.

Abstract: The disclosed invention relates to a process for conducting an equilibrium limited chemical reaction in a microchannel reactor. The process involves the use of active heat exchange and is suitable for conducting exothermic and endothermic reactions. The process is particularly suitable for synthesizing methanol and dimethyl ether.

Abstract: Novel methods of electroless plating are described. Catalyst coatings can be applied within microchannel apparatus. Various reactions, including combustion and steam reforming, can be conducted over electroless catalyst coatings.

Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.

Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.

Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.