Method for preventing plugging in the pyrolysis of agglomerative coals

Claim 2

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising comminuted particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the agglomerative coal for injection as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor having an inner surface and a minimum internal width greater than the maximum width of the opening, simultaneous with the discharge of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the agglomerative coal along the peripheral inner surface of the reactor, the diverging stream of particulate coal and solid source of heat combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor and wherein substantially all of the coal in the feed stream is formed of particles which detackify prior to contact with an interior surface of the pyrolysis reactor closest to the opening; (b) discharging the particulate source of heat and fluidizing gas into said mixing zone at a temperature greater than the temperature of the pyrolysis zone at a predetermined ratio of particulate source of heat to coal in the feed stream which is sufficient to maintain said pyrolysis zone at the pyrolysis temperature, while simultaneously injecting the particulate coal and carrier gas through the opening at a temperature less than the temperature at which the coal beings to tackify to form a resultant turbulent mixture of the particulate source of heat, the particulate coal and fluidizing and carrier gases in the mixing zone, the quantity of fluidizing gas discharged into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid particulate coal and yield a pyrolysis product stream containting as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the coal, and a vapor mixture of carrier gas and fluidizing gas and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 3

The process of claim 1 in which the pyrolysis temperature is above about 1060°R.

Claim 4

The process of claim 1 in which the pyrolysis temperature is in the range of from about 1060°R to about 2460°R.

Claim 5

The process of claim 1 in which the pyrolysis temperature is in the range of from 1360°R to about 2460°R.

Claim 6

The process of claim 1 in which the weight ratio of the solid particulate source of heat to coal in the feed stream is from about 2:1 to about 20:1.

Claim 7

A process for the production of hydrocarbon values from particulate, solid agglomerative coals in which solid agglomerative coal particles are injected in the presence of a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal particles as a turbulent flow, divergent jet stream from an opening positioned in an elongate pyrolysis reactor having an inner surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal particles along the inner peripheral surface of the reactor, the divergent stream of coal particles and solid source of heat combining in a mixing zone of the reactor and entering a pyrolysis zone of the reactor, comprising the following steps for preventing plugging of the reactor: (a) selecting for the pyrolysis reactor all but one of the variables: φ, the minimum time for a coal particle to travel from the opening to an interior fixed surface of the reactor in seconds; To, the introduction temperature of coal entering the pyrolysis reactor which is less than the temperature at which the coal begins to tackify in °R; Tp, the temperature of the pyrolysis zone in °R; and D, the maximum diameter of the particulate coal particles expressed in feet; (b) selecting a value for the unselected variable by simultaneous solution of the equations: ##EQU10## and ##EQU11## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination, in Btu/sec-ft-°R; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; τ is the plastic time constant for the coal at a predetermined solid source of heat to coal ratio in seconds; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; E 1 (x d ) is the exponential integral of x d = α/To; (c) injecting solid coal particles having a maximum particle diameter no greater than the selected diameter D, and said carrier gas from the opening into the mixing zone of the pyrolysis reactor at a temperature at least equal to the selected introduction temperature To, simultaneous with injecting the particulate source of heat and fluidizing gas into said mixing zone along the inner surface of said pyrolysis reactor at a predetermined ratio of particulate source of heat to coal particles sufficient to maintain said pyrolysis zone at a temperature at least equal to the selected pyrolysis temperature Tp, the reactor providing a minimum time for a coal particle to travel from the opening to an interior fixed surface of the reactor at least equal to the selected φ to form a resultant turbulent mixture of the particulate source of heat, the solid coal particles and the carrier and fluidizing gases in the mixing zone, the quantity of fluidizing gas injected into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (d) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid coal particles and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the coal particles, and a vapor mixture comprising carrier gas, fluidizing gas and a pyrolytic vapor comprising volatilized hydrocarbons.

Claim 8

A process for the production of hydrocarbon values from particulate, solid agglomerative coals in which solid agglomerative coal particles are injected in the presence of a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal particles as a turbulent flow, divergent jet stream from an opening positioned in an elongate pyrolysis reactor having an inner surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal particles along the inner peripheral surface of the reactor, the divergent stream of coal particles and solid source of heat combining in a mixing zone of the reactor and entering a pyrolysis zone of the reactor, comprising the following steps for preventing plugging of the reactor: (a) selecting for the pyrolysis reactor all but one of the variables: φ, the minimum time for a coal particle to travel from the opening to an interior fixed surface of the reactor in seconds; To, the introduction temperature of coal entering the pyrolysis reactor which is less than the temperature at which the coal begins to tackify in °R; Tp, the temperature of the pyrolysis zone in °R; and D, the maximum diameter of the particulate coal particles expressed in feet; (b) selecting a value for the unselected variable by simultaneous solution of the equations: ##EQU10## and ##EQU11## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination, in Btu/sec-ft-°R; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; τ is the plastic time constant for the coal at a predetermined solid source of heat to coal ratio in seconds; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; E 1 (x d ) is the exponential integral of x d = α/To; (c) injecting solid coal particles having a maximum particle diameter no greater than the selected diameter D, and said carrier gas from the opening into the mixing zone of the pyrolysis reactor at a temperature at least equal to the selected introduction temperature To, simultaneous with injecting the particulate source of heat and fluidizing gas into said mixing zone along the inner surface of said pyrolysis reactor at a predetermined ratio of particulate source of heat to coal particles sufficient to maintain said pyrolysis zone at a temperature at least equal to the selected pyrolysis temperature Tp, the reactor providing a minimum time for a coal particle to travel from the opening to an interior fixed surface of the reactor at least equal to the selected φ to form a resultant turbulent mixture of the particulate source of heat, the solid coal particles and the carrier and fluidizing gases in the mixing zone, the quantity of fluidizing gas injected into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (d) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid coal particles and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the coal particles, and a vapor mixture comprising carrier gas, fluidizing gas and a pyrolytic vapor comprising volatilized hydrocarbons.

Claim 9

The process of claim 6 in which Tp is above about 1060°R.

Claim 10

The process of claim 6 in which Tp is in the range of from about 1060°R to about 2460°R.

Claim 11

The process of claim 6 in which Tp is in the range of from 1360°R to about 2460°R.

Claim 12

The process of claim 6 in which the coal is a West Kentucky Coal and τ is the greater of 1×10 -9 sec or (3 - 0.7 Y) × 10 -9 sec wherein Y is the weight ratio of the solid particulate source of heat to coal.

Claim 13

The process of claim 6 in which α is 26,040°R.

Claim 14

The process of claim 10 in which α is 26,040°R.

Claim 15

The process of claim 6 in which the weight ratio of solid particulate source of heat to coal is selected from the range of about 2:1 to about 20:1.

Claim 16

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor, the reactor having an inner surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and solid source of heat combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor, and wherein substantially all of the particulate coal in the feed stream has a particle size less than a determined maximum diameter D, in feet, which is substantially satisfied by the two equations: ##EQU12## and ##EQU13## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination, in Btu/sec-ft-°R; φ is the minimum time required for a coal particle to travel from the opening to an interior fixed surface of the reactor in seconds; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; τ is the plastic time constant for the coal at a predetermined solid source of heat to coal ratio in seconds; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; and E 1 (x d ) is the exponential integral of x d = α/To; (b) injecting the particulate source of heat and fluidizing gas into said mixing zone at a temperature greater than Tp at a predetermined ratio of particulate source of heat to coal in the feed stream sufficient to maintain said pyrolysis zone at the pyrolysis temperature Tp, while simultaneously introducing the particulate agglomerative coal and said carrier gas from the opening into the mixing zone at the temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the particulate source of heat, the particulate agglomerative coal and the carrier and fluidizing gases in the mixing zone, the quantity of fluidizing gas injected into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate coal and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the particulate coal, and a vapor mixture of carrier and fluidizing gases and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 17

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor, the reactor having an inner surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and solid source of heat combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor, and wherein substantially all of the particulate coal in the feed stream has a particle size less than a determined maximum diameter D, in feet, which is substantially satisfied by the two equations: ##EQU12## and ##EQU13## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination, in Btu/sec-ft-°R; φ is the minimum time required for a coal particle to travel from the opening to an interior fixed surface of the reactor in seconds; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; τ is the plastic time constant for the coal at a predetermined solid source of heat to coal ratio in seconds; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; and E 1 (x d ) is the exponential integral of x d = α/To; (b) injecting the particulate source of heat and fluidizing gas into said mixing zone at a temperature greater than Tp at a predetermined ratio of particulate source of heat to coal in the feed stream sufficient to maintain said pyrolysis zone at the pyrolysis temperature Tp, while simultaneously introducing the particulate agglomerative coal and said carrier gas from the opening into the mixing zone at the temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the particulate source of heat, the particulate agglomerative coal and the carrier and fluidizing gases in the mixing zone, the quantity of fluidizing gas injected into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate coal and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the particulate coal, and a vapor mixture of carrier and fluidizing gases and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 18

The process of claim 14 in which Tp is above about 1060°R.

Claim 19

The process of claim 14 in which Tp is in the range of from about 1060°R to about 2460°R.

Claim 20

The process of claim 14 in which Tp is in the range of from 1360°R to about 2460°R.

Claim 21

The process of claim 14 in which the coal is a West Kentucky Coal and τ is the greater of 1×10 -9 sec or (3 - 0.7Y) × 10 -9 sec wherein Y is the weight ratio of the solid particulate source of heat to coal.

Claim 22

The process of claim 18 in which α is 26,040°R.

Claim 23

The process of claim 14 in which the coal is a West Kentucky Coal and α is 26,040°R.

Claim 24

The process of claim 14 in which the weight ratio of solid particulate source of heat to coal in the feed stream is selected from the range of about 2:1 to about 20:1.

Claim 25

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor, the reactor having an inner surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and solid source of heat combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor, the pyrolysis reactor having a configuration in which the minimum time required for a coal particle to travel from the opening to an interior fixed surface of the reactor in seconds is at least equal to θ as substantially satisfied by the two equations: ##EQU14## and ##EQU15## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination, in Btu/sec-ft-°R; θ is the tacky time for the largest coal particles in seconds; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; τ is the plastic time constant for the coal at a predetermined solid source of heat to coal ratio in seconds; α is the exponential temperature factor for detackification of the coal, °R: E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; E 1 (x d ) is the exponential integral of x d = α/To; (b) injecting the particulate source of heat and fluidizing gas into said mixing zone at a temperature greater than Tp at a predetermined ratio of particulate source of heat to coal in the feed stream sufficient to maintain said pyrolysis zone at the pyrolysis temperature Tp, while simultaneously introducing the particulate agglomerative coal and said carrier gas from the opening into the mixing zone at a temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the particulate source of heat, the particulate agglomerative coal and the carrier and fluidizing gases in the mixing zone, the quantity of fluidizing gas injected into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate coal and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the particulate coal, and a vapor mixture of carrier and fluidizing gases and pyrolytic vapors comprising volatilized hydrocarbaons.

Claim 26

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor, the reactor having an inner surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a particulate solid source of heat in a fluidizing gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and solid source of heat combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor, the pyrolysis reactor having a configuration in which the minimum time required for a coal particle to travel from the opening to an interior fixed surface of the reactor in seconds is at least equal to θ as substantially satisfied by the two equations: ##EQU14## and ##EQU15## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination, in Btu/sec-ft-°R; θ is the tacky time for the largest coal particles in seconds; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; τ is the plastic time constant for the coal at a predetermined solid source of heat to coal ratio in seconds; α is the exponential temperature factor for detackification of the coal, °R: E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; E 1 (x d ) is the exponential integral of x d = α/To; (b) injecting the particulate source of heat and fluidizing gas into said mixing zone at a temperature greater than Tp at a predetermined ratio of particulate source of heat to coal in the feed stream sufficient to maintain said pyrolysis zone at the pyrolysis temperature Tp, while simultaneously introducing the particulate agglomerative coal and said carrier gas from the opening into the mixing zone at a temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the particulate source of heat, the particulate agglomerative coal and the carrier and fluidizing gases in the mixing zone, the quantity of fluidizing gas injected into said mixing zone with the particulate source of heat being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate coal and yield a pyrolysis product stream containing as solids, the particulate source of heat and a carbon containing solid residue of pyrolysis of the particulate coal, and a vapor mixture of carrier and fluidizing gases and pyrolytic vapors comprising volatilized hydrocarbaons.

Claim 27

The process of claim 22 in which Tp is above about 1060°R.

Claim 28

The process of claim 22 in which Tp is in the range of from about 1060°R to about 2460°R.

Claim 29

The process of claim 22 in which Tp is in the range of from 1360°R to about 2460°R.

Claim 30

The process of claim 22 in which the coal is a West Kentucky Coal and τ is the greater of 1×10 -9 sec or (3 - 0.7Y) × 10 -9 sec wherein Y is the weight ratio of the solid particulate source of heat to coal.

Claim 31

The process of claim 26 in which α is 26,040°R.

Claim 32

The process of claim 22 in which the coal is a West Kentucky Coal and α is 26,040°R.

Claim 33

The process of claim 22 in which the weight ratio of solid particulate source of heat to coal in the feed stream is selected from the range of about 2:1 to about 20:1.

Claim 34

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising comminuted particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor, the reactor having a peripheral inner surface and a pyrolysis zone, the minimum width of the pyrolysis reactor being greater than the maximum width of the opening, simultaneous with the injection of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the peripheral inner surface of the reactor, the divergent feed stream of particulate coal and the fluid combining in the mixing zone of the reactor prior to passage to a pyrolysis zone, wherein substantially all of the coal in the feed is selectively formed of particles which detackify prior to contact with an interior surface of the pyrolysis reactor closest to the opening; (b) injecting the gaseous fluid along the peripheral inner surface of the reactor while simultaneously introducing the particulate coal feed stream into the mixing zone through the opening at a temperature less than the temperature at which the coal begins to tackify to form a resultant turbulent mixture of the fluid, the particulate coal and the carrier gas in the mixing zone, the quantity of the gaseous fluid injected along the peripheral inner surface being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor maintained at a pyrolysis temperature sufficient to pyrolyze the solid particulate coal and yield a pyrolysis product stream containing as solids, a carbon containing solid residue of pyrolysis of the coal in the feed stream, and a vapor mixture of the fluid, the carrier gas and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 35

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising comminuted particulate agglomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor, the reactor having a peripheral inner surface and a pyrolysis zone, the minimum width of the pyrolysis reactor being greater than the maximum width of the opening, simultaneous with the injection of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the peripheral inner surface of the reactor, the divergent feed stream of particulate coal and the fluid combining in the mixing zone of the reactor prior to passage to a pyrolysis zone, wherein substantially all of the coal in the feed is selectively formed of particles which detackify prior to contact with an interior surface of the pyrolysis reactor closest to the opening; (b) injecting the gaseous fluid along the peripheral inner surface of the reactor while simultaneously introducing the particulate coal feed stream into the mixing zone through the opening at a temperature less than the temperature at which the coal begins to tackify to form a resultant turbulent mixture of the fluid, the particulate coal and the carrier gas in the mixing zone, the quantity of the gaseous fluid injected along the peripheral inner surface being at least sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor maintained at a pyrolysis temperature sufficient to pyrolyze the solid particulate coal and yield a pyrolysis product stream containing as solids, a carbon containing solid residue of pyrolysis of the coal in the feed stream, and a vapor mixture of the fluid, the carrier gas and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 36

The process of claim 30 in which the pyrolysis temperature is above about 1060°R.

Claim 37

The process of claim 30 in which the pyrolysis temperature is in the range of from about 1060°R to about 2460°R.

Claim 38

The process of claim 30 in which the pyrolysis temperature is in the range of from 1360°R to about 2460°R.

Claim 39

A process for the production of hydrocarbon values from particulate, solid agglomerative coals in which particulate, solid agglomerative coal is injected in the presence of a carrier gas which is nondeleteriously reactive with respect to the products of pyrolysis of the coal as a turbulent flow, divergent jet stream from an opening positioned in an elongate pyrolysis reactor having an inner surface, the maximum width of the opening being less than the minimum width of the reactor, simultaneous with the injection of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the coal and carrier gas and fluid combining in a mixing zone of the reactor and entering a pyrolysis zone, comprising the following steps for preventing plugging of the reactor: (a) selecting for the pyrolysis reactor all but one of the variables: φ, the minimum time for the coal particles to reach an internal surface of the reactor from the opening in seconds; To, the initial temperature of coal entering the pyrolysis reactor in °R; Tp, the temperature of the pyrolysis zone in °R; and D, the diameter of the particulate solid coal expressed in feet; (b) selecting a value for the unselected variable by simultaneous solution of the equations: ##EQU16## and ##EQU17## K is the thermal conductivity of the carrier and fluidizing gases, in Btu/sec-ft-°R; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb.-°R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; E 1 (x d ) is the exponential integral of x d = α/To; (c) injecting the gaseous fluid along the reactor inner peripheral surface simultaneous with injecting the particulate coal and said carrier gas at the temperature To, which is less than the temperature at which the coal begins to tackify, from the opening into said mixing zone of the pyrolysis reactor, which provides a minimum time for a coal particle to travel from the opening to an interior fixed surface for the reactor at least equal to the selected φ, to form a resultant turbulent mixture of the particulate coal, carrier gas and fluid in the mixing zone, the quantity of the gaseous fluid injected being at least sufficient to prevent backflow of the coal from the divergent stream; and (d) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid particulate coal and yield a pyrolysis product stream containing a carbon containing solid residue of pyrolysis of the coal, and a vapor mixture of carrier gas, gaseous fluid and a pyrolytic vapor comprising volatilized hydrocarbons.

Claim 40

A process for the production of hydrocarbon values from particulate, solid agglomerative coals in which particulate, solid agglomerative coal is injected in the presence of a carrier gas which is nondeleteriously reactive with respect to the products of pyrolysis of the coal as a turbulent flow, divergent jet stream from an opening positioned in an elongate pyrolysis reactor having an inner surface, the maximum width of the opening being less than the minimum width of the reactor, simultaneous with the injection of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the coal and carrier gas and fluid combining in a mixing zone of the reactor and entering a pyrolysis zone, comprising the following steps for preventing plugging of the reactor: (a) selecting for the pyrolysis reactor all but one of the variables: φ, the minimum time for the coal particles to reach an internal surface of the reactor from the opening in seconds; To, the initial temperature of coal entering the pyrolysis reactor in °R; Tp, the temperature of the pyrolysis zone in °R; and D, the diameter of the particulate solid coal expressed in feet; (b) selecting a value for the unselected variable by simultaneous solution of the equations: ##EQU16## and ##EQU17## K is the thermal conductivity of the carrier and fluidizing gases, in Btu/sec-ft-°R; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb.-°R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; E 1 (x d ) is the exponential integral of x d = α/To; (c) injecting the gaseous fluid along the reactor inner peripheral surface simultaneous with injecting the particulate coal and said carrier gas at the temperature To, which is less than the temperature at which the coal begins to tackify, from the opening into said mixing zone of the pyrolysis reactor, which provides a minimum time for a coal particle to travel from the opening to an interior fixed surface for the reactor at least equal to the selected φ, to form a resultant turbulent mixture of the particulate coal, carrier gas and fluid in the mixing zone, the quantity of the gaseous fluid injected being at least sufficient to prevent backflow of the coal from the divergent stream; and (d) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid particulate coal and yield a pyrolysis product stream containing a carbon containing solid residue of pyrolysis of the coal, and a vapor mixture of carrier gas, gaseous fluid and a pyrolytic vapor comprising volatilized hydrocarbons.

Claim 41

The process of claim 34 in which Tp is above about 1060°R.

Claim 42

The process of claim 34 in which Tp is in the range of from about 1060°R to about 2460°R.

Claim 43

The process of claim 34 in which Tp is in the range of from 1360°R to about 2460°R.

Claim 44

The process of claim 34 in which the coal is a West Kentucky Coal and α is 26,040°R.

Claim 45

A process for the production of hydrocarbon values from particulate, solid aggomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate aggomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for injection as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor having an inner peripheral surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the discharge of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and gaseous fluid combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor and wherein substantially all of the coal feed formed has a particle size less than a determined maximum diameter D, in feet, which is substantially satisfied by the two equations: ##EQU18## and ##EQU19## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination in Btu/sec-ft-°R; φ is the minimum time required for a coal particle to travel from the opening to an internal fixed surface in the reactor in seconds; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; α is the exponential temperature factor for detackification of the coal, ° R.; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; and E 1 (x d ) is the exponential integral of x d = α/To; (b) discharging the fluid into said mixing zone simultaneous with introducing the particulate coal and carrier gas from the opening into the mixing zone at a temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the carrier gas, particulate coal and fluid in the mixing zone, the quantity of the gaseous fluid discharged into said mixing zone being sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate coal and yield a pyrolysis product stream containing solid residue of pyrolysis of the coal, and a vapor mixture comprising carrier gas and gaseous fluid and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 46

A process for the production of hydrocarbon values from particulate, solid aggomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate aggomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for injection as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor having an inner peripheral surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the discharge of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and gaseous fluid combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor and wherein substantially all of the coal feed formed has a particle size less than a determined maximum diameter D, in feet, which is substantially satisfied by the two equations: ##EQU18## and ##EQU19## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination in Btu/sec-ft-°R; φ is the minimum time required for a coal particle to travel from the opening to an internal fixed surface in the reactor in seconds; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; α is the exponential temperature factor for detackification of the coal, ° R.; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; and E 1 (x d ) is the exponential integral of x d = α/To; (b) discharging the fluid into said mixing zone simultaneous with introducing the particulate coal and carrier gas from the opening into the mixing zone at a temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the carrier gas, particulate coal and fluid in the mixing zone, the quantity of the gaseous fluid discharged into said mixing zone being sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the particulate coal and yield a pyrolysis product stream containing solid residue of pyrolysis of the coal, and a vapor mixture comprising carrier gas and gaseous fluid and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 47

The process of claim 39 in which Tp is above about 1060°R.

Claim 48

The process of claim 39 in which Tp is in the range of from about 1060°R to about 2460°R.

Claim 49

The process of claim 39 in which Tp is in the range of from 1360°R to about 2460°R.

Claim 50

The process of claim 39 in which the coal is a West Kentucky Coal and τ is 26,040°R.

Claim 51

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate aggomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor having an inner peripheral surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and gaseous fluid combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor, the pyrolysis reactor having a configuration in which the minimum time required for a coal particle to travel from the opening to an interior fixed surface of the reactor, in seconds, is at least equal to θ as substantially satisfied by the two equations: ##EQU20## and ##EQU21## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination in Btu/sec-ft-°R; θ is the tacky time for the largest coal particles in seconds; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; and E 1 (x d ) is the exponential integral of x d = α/To; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; (b) discharging the fluid into said mixing zone simultaneous with injecting the solid particulate coal and said carrier gas from the opening into the mixing zone at a temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the carrier gas, particulate coal and gaseous fluid in the mixing zone, the quantity of gaseous fluid discharged into said mixing zone being sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid particulate coal and yield a pyrolysis product stream containing a carbon containing solid residue of pyrolysis of the coal, and a vapor mixture of carrier gas and gaseous fluid and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 52

A process for the production of hydrocarbon values from particulate, solid agglomerative coals comprising the steps of: (a) forming a particulate coal feed stream comprising particulate aggomerative coal and a carrier gas which is substantially nondeleteriously reactive with respect to products of pyrolysis of the coal for introduction as a turbulent, diverging jet stream from an opening into a mixing zone of an elongate pyrolysis reactor having an inner peripheral surface, the maximum width of the opening being less than the minimum internal width of the reactor, simultaneous with the injection of a gaseous fluid which is substantially nondeleteriously reactive with respect to the products of pyrolysis of the coal along the inner peripheral surface of the reactor, the divergent stream of particulate coal and gaseous fluid combining in the mixing zone of the reactor prior to passage to a pyrolysis zone of the reactor, the pyrolysis reactor having a configuration in which the minimum time required for a coal particle to travel from the opening to an interior fixed surface of the reactor, in seconds, is at least equal to θ as substantially satisfied by the two equations: ##EQU20## and ##EQU21## wherein K is the thermal conductivity of the carrier and fluidizing gases, in combination in Btu/sec-ft-°R; θ is the tacky time for the largest coal particles in seconds; α is the exponential temperature factor for detackification of the coal, °R; E 1 (x a ) is the exponential integral of x a = (α/Tt - α/Tp); E 1 (x b ) is the exponential integral of x b = (α/To - α/Tp); E 1 (x c ) is the exponential integral of x c = α/Tt; and E 1 (x d ) is the exponential integral of x d = α/To; ρ is the apparent particle density of the coal, lb/ft 3 ; C is the specific heat of the coal, Btu/lb-°R; Tp is the temperature of pyrolysis in °R; To is the introduction temperature of the coal in °R; Tt is the temperature of the coal at the end of the tacky period of the coal in °R; (b) discharging the fluid into said mixing zone simultaneous with injecting the solid particulate coal and said carrier gas from the opening into the mixing zone at a temperature To, which is below the temperature at which the coal begins to tackify, to form a resultant turbulent mixture of the carrier gas, particulate coal and gaseous fluid in the mixing zone, the quantity of gaseous fluid discharged into said mixing zone being sufficient to prevent backflow of the coal from the divergent stream; and (c) passing the resultant turbulent mixture from said mixing zone to the pyrolysis zone of said pyrolysis reactor to pyrolyze the solid particulate coal and yield a pyrolysis product stream containing a carbon containing solid residue of pyrolysis of the coal, and a vapor mixture of carrier gas and gaseous fluid and pyrolytic vapors comprising volatilized hydrocarbons.

Claim 53

The process of claim 44 in which Tp is above about 1060°R.

Claim 54

The process of claim 44 in which Tp is in the range of from about 1060°R to about 2460°R.

Claim 55

The process of claim 44 in which Tp is in the range of from 1360°R to about 2460°R.

Claim 56

The process of claim 44 in which the coal is a West Kentucky Coal and α is 26,040°R.