Hydroconversion of coal in a hydrogen donor solvent with an oil-soluble catalyst

Claim 2

A process for hydroconverting coal to produce an oil, which comprises the steps of: (a) forming a mixture of coal, a hydrogen donor solvent comprising at least 30 weight percent of hydrogen donor compounds and an added oil-soluble metal compound, said metal being selected from the group consisting of Groups VB, VIB, VIIB and VIII of the Periodic Table of Elements and mixtures thereof; (b) converting said oil-soluble compound to a catalyst within said mixture in the presence of a hydrogen-containing gas by heating said mixture to an elevated temperature; (c) reacting the resulting mixture containing said catalyst with hydrogen under coal hydroconversion conditions, in a hydroconversion zone; (d) removing from said hydroconversion zone an effluent comprising an oil product and solids; (e) separating said oil product into at least a light fraction, an intermediate fraction and a heavy fraction; and (f) recycling, without intervening hydrogenation, at least a portion of said intermediate fraction as solvent to said hydroconversion zone.

Claim 3

The process of claim 1 wherein said oil soluble metal compound in step (a) is added in an amount ranging from about 10 to less than 2000 weight parts per million, calculated as the elemental metal, based on the weight of the coal in said mixture.

Claim 4

The process of claim 1 wherein said oil soluble metal compound is selected from the group consisting of inorganic compounds, salts of organic acids, organometallic compounds and salts of organic amines.

Claim 5

The process of claim 1 wherein said oil soluble metal compound is selected from the group consisting of salts of acyclic aliphatic carboxylic acids and salts of alicyclic aliphatic carboxylic acids.

Claim 6

The process of claim 1 wherein said oil soluble metal compound is a salt of naphthenic acid.

Claim 7

The process of claim 1 wherein the metal constituent of said oil soluble metal compound is selected from the group consisting of molybdenum, chromium and vanadium.

Claim 8

The process of claim 1 wherein said oil soluble metal compound is molybdenum naphthenate.

Claim 9

The process of claim 1 wherein said hydrogen-containing gas of step (b) comprises from about 1 to 90 mole percent hydrogen sulfide.

Claim 10

The process of claim 1 wherein said hydrogen-containing gas of step (b) comprises from about 1 to 50 mole percent hydrogen sulfide.

Claim 11

The process of claim 1 wherein said oil soluble metal compound is converted to a catalyst by subjecting said mixture to a temperature range selected from the group consisting of a temperature ranging from about 343° C. to about 538° C. in said hydroconversion zone maintained under hydroconversion conditions and a temperature ranging from about 325° to about 415° C. prior to said hydroconversion step.

Claim 12

The process of claim 1 wherein said oil soluble metal compound is converted by first heating the mixture of said soluble metal compound, coal and hydrogen donor solvent to a temperature ranging from about 325° C. to about 415° C. in the presence of said hydrogen-containing gas to form a catalyst within said mixture and subsequently reacting the resulting mixture containing the catalyst with hydrogen under hydroconversion conditions.

Claim 13

The process of claim 11 wherein said hydrogen-containing gas also contains hydrogen sulfide.

Claim 14

The process of claim 1 wherein said oil soluble metal compound is converted in the presence of a hydrogen containing gas in the hydroconversion zone under hydroconversion conditions thereby forming said catalyst in situ within said mixture in the hydroconversion zone.

Claim 15

The process of claim 1 wherein said hydroconversion conditions include a temperature ranging from about 343° C. to about 538° C. (649.4° to 1000° F.) and a hydrogen partial pressure ranging from 500 to 5000 psig.

Claim 16

The process of claim 1 wherein the space velocity of said mixture in said hydroconversion zone ranges from about 0.1 to 10 volumes of mixture per hour per volume of hydroconversion zone.

Claim 17

The process of claim 1 comprising the additional steps of separating at least a portion of said solids from said hydroconversion zone effluent and recycling at least a portion of said separated solids to said hydroconversion zone.

Claim 18

The process of claim 1 wherein said catalyst is the sole catalyst in said hydroconversion zone.

Claim 19

The process of claim 1 wherein said solvent and coal are mixed in a solvent-to-coal weight ratio ranging from about 0.8:1 to about 4:1.

Claim 20

The process of claim 1 wherein said solvent and coal are mixed in a solvent-to-coal weight ratio ranging from about 1:1 to 2:1.

Claim 21

The process of claim 1 wherein said oil soluble metal compound is converted to a catalyst by subjecting said mixture to a temperature ranging from about 343° to about 538° C. in said hydroconversion zone under hydroconversion conditions.

Claim 22

A process for hydroconverting coal to produce an oil product, which comprises: (a) forming a mixture of coal, hydrogen donor solvent and an oil soluble metal compound, said compound being added in an amount ranging from about 10 to less than 2000 weight parts per million, calculated as the elemental metal, based on the weight of the coal in said mixture, said metal being selected from the group consisting of Groups VB, VIB, VIIB and VIII of the Periodic Table of Elements and mixtures thereof; (b) heating the mixture resulting from step (a) to a temperature ranging from about 325° C. to about 415° C. in the presence of a hydrogen-containing gas to form a catalyst within said mixture; (c) reacting the resulting mixture containing said catalyst with hydrogen under hydroconversion conditions including a temperature ranging from about 343° C. to about 538° C. (649.4° F. to 1000° F.) and a hydrogen pressure ranging from about 500 to about 5000 psig; (d) removing from said hydroconversion zone an effluent comprising an oil product and solids; (e) separating said oil product into at least a light fraction, an intermediate fraction and a heavy fraction; and (f) recycling, without intervening hydrogenation, at least a portion of said intermediate fraction as solvent to said hydroconversion zone.

Claim 23

A process for hydroconverting coal to produce an oil product, which comprises: (a) forming a mixture of coal, hydrogen donor solvent and an oil soluble metal compound, said compound being added in an amount ranging from about 10 to less than 2000 weight parts per million, calculated as the elemental metal, based on the weight of the coal in said mixture, said metal being selected from the group consisting of Groups VB, VIB, VIIB and VIII of the Periodic Table of Elements and mixtures thereof; (b) heating the mixture resulting from step (a) to a temperature ranging from about 325° C. to about 415° C. in the presence of a hydrogen-containing gas to form a catalyst within said mixture; (c) reacting the resulting mixture containing said catalyst with hydrogen under hydroconversion conditions including a temperature ranging from about 343° C. to about 538° C. (649.4° F. to 1000° F.) and a hydrogen pressure ranging from about 500 to about 5000 psig; (d) removing from said hydroconversion zone an effluent comprising an oil product and solids; (e) separating said oil product into at least a light fraction, an intermediate fraction and a heavy fraction; and (f) recycling, without intervening hydrogenation, at least a portion of said intermediate fraction as solvent to said hydroconversion zone.

Claim 24

A process for hydroconverting coal to produce an oil, which comprises the steps of: (a) forming a mixture of wet coal, a hydrogen donor solvent comprising at least 30 weight percent of hydrogen donor compounds and an added oil-soluble metal compound, said oil soluble compound being added in an amount ranging from about 10 to about 700 wppm, calculated as the elemental metal, based on the coal in said mixture, said metal being selected from the group consisting of Groups VB, VIB, VIIB and VIII of the Periodic Table of Elements and mixtures thereof; (b) converting said oil-soluble compound to a catalyst within said mixture in the presence of a hydrogen-containing gas by heating said mixture to be an elevated temperature; (c) reacting the resulting mixture containing said catalyst with a gas comprising hydrogen and from about 5 to about 50 mole percent carbon monoxide, under coal hydroconversion conditions, in a hydroconversion zone; and (d) recovering an oil product.

Claim 25

A process for hydroconverting coal to produce an oil, which comprises the steps of: (a) forming a mixture of wet coal, a hydrogen donor solvent comprising at least 30 weight percent of hydrogen donor compounds and an added oil-soluble metal compound, said oil soluble compound being added in an amount ranging from about 10 to about 700 wppm, calculated as the elemental metal, based on the coal in said mixture, said metal being selected from the group consisting of Groups VB, VIB, VIIB and VIII of the Periodic Table of Elements and mixtures thereof; (b) converting said oil-soluble compound to a catalyst within said mixture in the presence of a hydrogen-containing gas by heating said mixture to be an elevated temperature; (c) reacting the resulting mixture containing said catalyst with a gas comprising hydrogen and from about 5 to about 50 mole percent carbon monoxide, under coal hydroconversion conditions, in a hydroconversion zone; and (d) recovering an oil product.

Claim 26

The process of claim 22 wherein said oil soluble metal compound is added to step (a) in an amount ranging from about 50 to 500 wppm, calculated as the elemental metal, based on the coal.

Claim 27

The process of claim 22 wherein said oil soluble metal compound is a metal-containing organic compound.

Claim 28

The process of claim 22 wherein said oil soluble metal compound is a molybdenum-containing organic compound.

Claim 29

A process for hydroconverting coal to produce an oil, which comprises the steps of: (a) forming a mixture of wet coal, a hydrogen donor solvent comprising at least 30 weight percent of hydrogen donor compounds and an added oil-soluble molybdenum-containing organic compound, said organic compound being added in an amount ranging from about 10 to less than 2000 wppm, calculated as the elemental metal, based on the coal in said mixture; (b) converting said organic compound to a catalyst within said mixture in the presence of a hydrogen-containing gas by heating said mixture to an elevated temperature; (c) reacting the resulting mixture containing said catalyst with a gas comprising hydrogen and from about 5 to about 50 mole percent carbon monoxide, under coal hydroconversion conditions; and (d) recovering an oil product.

Claim 30

A process for hydroconverting coal to produce an oil, which comprises the steps of: (a) forming a mixture of wet coal, a hydrogen donor solvent comprising at least 30 weight percent of hydrogen donor compounds and an added oil-soluble molybdenum-containing organic compound, said organic compound being added in an amount ranging from about 10 to less than 2000 wppm, calculated as the elemental metal, based on the coal in said mixture; (b) converting said organic compound to a catalyst within said mixture in the presence of a hydrogen-containing gas by heating said mixture to an elevated temperature; (c) reacting the resulting mixture containing said catalyst with a gas comprising hydrogen and from about 5 to about 50 mole percent carbon monoxide, under coal hydroconversion conditions; and (d) recovering an oil product.

Claim 31

The process of claim 26 wherein said organic compound is selected from the group consisting of salts or organic acids, organometallic compounds and salts of organic amines.

Claim 32

The process of claim 26 wherein said organic compound is selected from the group consisting of salts of acyclic aliphatic carboxylic acids and salts of alicyclic aliphatic carboxylic acids.

Claim 33

The process of claim 26 wherein said organic compound is molybdenum naphthenate.

Claim 34

The process of claim 26 wherein said hydrogen containing gas of step (b) comprises from about 1 to 90 mole percent hydrogen sulfide.

Claim 35

The process of claim 26 wherein the gas of step (c) additionally comprises from about 1 to about 30 mole percent hydrogen sulfide.