Short residence time low pressure hydropyrolysis of carbonaceous materials

Claim 2

A process for treating carbonaceous material with hydrogen, in the absence of added catalyst, to produce a high yield of carbonaceous tars, comprising, in serial combination, a. adding liquid or crushed solid carbonaceous material into a first reaction zone of a reactor having at least two reaction zones; and a pressure of between atmospheric pressure and 450 psia; b. adding hot hydrogen to the stream of carbonaceous material to effect a reaction with same to produce reaction products at a temperature of between 400° C and 2000° C.; c. quenching the mixture of step (b) while insuring that the total residence time of heat-up, reaction and quenching of said mixture varies from about 2 milliseconds to about 2 seconds; d. removing at least a portion of the reaction products from said quenched mixture of step (c); and e. introducing the residual carbonaceous material into a subsequent reaction zone and repeating steps (a) - (d) for said subsequent reaction zone.

Claim 3

The process of claim 1, wherein the crushed solid material has an average particle size smaller than about 1/2 inch.

Claim 4

The process of claim 2, wherein the ratio of carbonaceous material to hydrogen, in the carbonaceous material-hydrogen mixture in each of said reaction zones varies from about 0.05 to about 4.

Claim 5

The process of claim 3, wherein the heat-up time of said carbonaceous material is between about 500° C/sec and 300,000° C/sec.

Claim 6

The process of claim 4, wherein the temperature of the quenched mixture in each reaction zone does not exceed about 200° C.

Claim 7

The process of claim 5, wherein the quenching material is hydrogen at a temperature below 200° C and the carbonaceous material is coal.

Claim 8

The process of claim 6 wherein said reaction zones are superimposed with respect to each other.

Claim 9

The process of claim 7 wherein said reaction products are removed from the surface of the carbonaceous material.

Claim 10

The process of claim 8 wherein said reaction includes five reaction zones and said carbonaceous material is gravity fed through each of said reaction zones.

Claim 11

A process for converting coal into coal tars comprising the steps of: a. Introducing a continuous stream of finely divided coal into a first reaction zone of of a pressure vessel having at least two reaction zones and a pressure between atmospheric pressure and 450 psia; b. continuously adding hot hydrogen to the first reaction zone of the pressure vessel so as to impinge the coal stream and effect a reaction with same to produce coal tars reaction products at a temperature between about 400° C and about 2000° C; c. subsequently quenching the hot hydrogen-coal stream within the first reaction zone with cold hydrogen; d. limiting the total residence time of heat-up, reaction, and quenching of said mixture within the first reaction zone of the vessel to a period of less than 2 seconds; e. removing at least a portion of the coal tars from the quenched hydrogen-coal stream; and f. introducing the residual coal into a subsequent reaction zone and repeating the steps (a) - (e) for the subsequent reaction zone.

Claim 12

A process for converting coal into coal tars comprising the steps of: a. Introducing a continuous stream of finely divided coal into a first reaction zone of of a pressure vessel having at least two reaction zones and a pressure between atmospheric pressure and 450 psia; b. continuously adding hot hydrogen to the first reaction zone of the pressure vessel so as to impinge the coal stream and effect a reaction with same to produce coal tars reaction products at a temperature between about 400° C and about 2000° C; c. subsequently quenching the hot hydrogen-coal stream within the first reaction zone with cold hydrogen; d. limiting the total residence time of heat-up, reaction, and quenching of said mixture within the first reaction zone of the vessel to a period of less than 2 seconds; e. removing at least a portion of the coal tars from the quenched hydrogen-coal stream; and f. introducing the residual coal into a subsequent reaction zone and repeating the steps (a) - (e) for the subsequent reaction zone.

Claim 13

The method of claim 10, wherein: a. The coal has an average particle size of less than about 1/2 inch; b. the hydrogen/coal weight ratio of the reaction mixture in each reaction zone varies from about 0.05 to about 4; c. the reaction temperature varies from about 500° C. to about 1500° C; d. the total residence time of hydrogen and coal in each reaction zone is not more than about 1 second; e. the cold hydrogen quenched stream has a temperature of below about 200° C; and f. the separated liquid hydrocarbon stream is further processed.

Claim 14

The method of claim 10, wherein the separated coal tars are further processed, said coal tars having compounds which include bewtween about 10 to 80 carbon atoms.