Coal deashing process having improved solvent recovery techniques

Claim 2

A process comprising: mixing in a first mixing zone a process solvent with coal; solubilizing the coal at elevated temperature and pressure and flashing the resultant mixture to produce a prepared mixture comprising soluble coal products, insoluble coal products and some of the process solvent; mixing the prepared mixture with a deashing solvent in a second mixing zone to provide a feed mixture, said deashing solvent consisting essentially of at least one substance having a critical temperature below 800 degrees F. selected from the group consisting of aromatic hydrocarbons having a single benezene nucleus and normal boiling points below about 310 degrees F., cycloparaffin hydrocarbons having normal boiling points below about 310 degrees F., open chain mono-olefin hydrocarbons having normal boiling points below about 310 degrees F., open chain saturated hydrocarbons having normal boiling points below about 310 degrees F., mono-, di, and tri-open chain amines containing from about 2-8 carbon atoms, carbocyclic amines having a monocyclic structure containing from about 6-9 carbon atoms, heterocyclic amines containing from about 5-9 carbon atoms, and phenols containing from about 6-9 carbon atoms and their homologs; introducing the feed mixture into a first separation zone and separating said mixture into a first heavy fraction comprising insoluble coal products and some deashing solvent and first light fraction comprising soluble coal products, deashing solvent and some process solvent; withdrawing the first heavy fraction from the first separation zone; introducing the first light fraction into a third mixing zone; introducing at least a portion of a third light fraction from a third separation zone into the third mixing zone to mix with the first light fraction contained therein; withdrawing the mixture from the third mixing zone; introducing the mixture into a second separation zone; separating the mixture in the second separation zone into a second heavy fraction comprising soluble coal products and some deashing solvent and a second light fraction comprising deashing solvent and some process solvent; withdrawing the second heavy fraction from the second separation zone; withdrawing the second light fraction from the second separation zone; introducing the second light fraction into a third separation zone; separating the second light fraction into a third heavy fraction comprising process solvent and a third light fraction comprising deashing solvent; withdrawing the third light fraction from the third separation zone; returning at least a portion of the third light fraction comprising deashing solvent to the third mixing zone for introduction therein; returning the remaining third light fraction to the second mixing zone to aid in providing the feed mixture; withdrawing the third heavy fraction from the third separation zone; and returning at least a portion of the third heavy fraction to the first mixing zone to aid in solubilizing said coal.

Claim 3

The process of claim 1 defined further to include the steps of: flashing the withdrawn first heavy fraction in a second flash zone to produce one stream comprising insoluble coal products and one other stream comprising deashing solvent and; flashing the second heavy fraction in a third flash zone to produce one stream comprising soluble coal products and one other stream comprising deashing solvent.

Claim 4

The process of claim 1 defined further to include the step of: maintaining the first separation zone at a temperature level in a range of from about 400 degrees F. to about 620 degrees F. and a pressure level in a range of from about 500 psig to about 1500 psig to effect the separation of the feed mixture.

Claim 5

The process of claim 1 defined further to include the step of: maintaining the second separation zone at a temperature level in the range of from about 500 degrees F. to about 900 degrees F. and a pressure level in a range of from about 300 psig to about 1500 psig to effect the separation within the second separation zone.

Claim 6

The process of claim 1 defined further to include the step of: maintaining the third separation zone at an elevated temperature and a pressure level in a range of from atmospheric pressure to about 1500 psig to effect the separation in the third separation zone.

Claim 7

A process comprising: mixing in a first mixing zone a process solvent with coal; solubilizing the coal at elevated temperature and pressure and flashing the resultant mixture to produce a prepared mixture comprising the process solvent, soluble coal products and insoluble coal products; mixing the prepared mixture with a deashing solvent in a second mixing zone to provide a feed mixture, said deashing solvent consisting essentially of at least one substance having a critical temperature below 800 degrees F. selected from the group consisting of aromatic hydrocarbons having a single benzene nucleus and normal boiling points below about 310 degrees F., cycloparaffin hydrocarbons having normal boiling points below about 310 degrees F., open chain mono-olefin hydrocarbons having normal boiling points below about 310 degrees F., open chain saturated hydrocarbons having normal boiling points below about 310 degrees F., mono-, di, and tri-open chain amines containing from about 2-8 carbon atoms, carbocyclic amines having a monocyclic structure containing from about 6-9 carbon atoms, heterocyclic amines containing from about 5-9 carbon atoms, and phenols containing from about 6-9 carbon atoms and their homologs; introducing the feed mixture into a first separation zone; separating the feed mixture in the first separation zone into a first heavy fraction comprising insoluble coal products and some deashing solvent and a first light fraction comprising soluble coal products, deashing solvent and some process solvent; withdrawing the first heavy fraction from the first separation zone; withdrawing the first light fraction from the first separation zone; introducing the first light fraction into a third mixing zone; mixing the first light fraction with a least a portion of a fourth light fraction obtained from a fourth separation zone to form a mixture; withdrawing the mixture from the third mixing zone; introducing the mixture into a second separation zone; separating the mixture in the second separation zone into a second heavy fraction comprising soluble coal products, some deashing solvent and some process solvent and a second light fraction comprising deashing solvent and some process solvent; withdrawing the second heavy fraction from the second separation zone; withdrawing the second light fraction from the second separation zone; introducing the second light fraction into a third separation zone; separating the second light fraction in the third separation zone into a third heavy fraction comprising process solvent and a third light fraction comprising deashing solvent; withdrawing the third heavy fraction from the third separation zone; withdrawing the third light fraction from the third separation zone; passing at least a portion of the third light fraction to the second mixing zone to aid in providing the feed mixture; introducing the remaining third light fraction into a fourth separation zone; introducing the second heavy fraction withdrawn from the second separation zone into the fourth separation zone; separating the second heavy fraction and third light fraction in the fourth separation zone into a fourth heavy fraction comprising soluble coal products and some deashing solvent and a fourth light fraction comprising deashing solvent and some process solvent; withdrawing the fourth heavy fraction from the fourth separation zone; withdrawing the fourth light fraction from the fourth separation zone; and passing at least a portion of the fourth light fraction withdrawn from the fourth separation zone into the third mixing zone to mix with the first light fraction contained therein.

Claim 8

A process comprising: mixing in a first mixing zone a process solvent with coal; solubilizing the coal at elevated temperature and pressure and flashing the resultant mixture to produce a prepared mixture comprising the process solvent, soluble coal products and insoluble coal products; mixing the prepared mixture with a deashing solvent in a second mixing zone to provide a feed mixture, said deashing solvent consisting essentially of at least one substance having a critical temperature below 800 degrees F. selected from the group consisting of aromatic hydrocarbons having a single benzene nucleus and normal boiling points below about 310 degrees F., cycloparaffin hydrocarbons having normal boiling points below about 310 degrees F., open chain mono-olefin hydrocarbons having normal boiling points below about 310 degrees F., open chain saturated hydrocarbons having normal boiling points below about 310 degrees F., mono-, di, and tri-open chain amines containing from about 2-8 carbon atoms, carbocyclic amines having a monocyclic structure containing from about 6-9 carbon atoms, heterocyclic amines containing from about 5-9 carbon atoms, and phenols containing from about 6-9 carbon atoms and their homologs; introducing the feed mixture into a first separation zone; separating the feed mixture in the first separation zone into a first heavy fraction comprising insoluble coal products and some deashing solvent and a first light fraction comprising soluble coal products, deashing solvent and some process solvent; withdrawing the first heavy fraction from the first separation zone; withdrawing the first light fraction from the first separation zone; introducing the first light fraction into a third mixing zone; mixing the first light fraction with a least a portion of a fourth light fraction obtained from a fourth separation zone to form a mixture; withdrawing the mixture from the third mixing zone; introducing the mixture into a second separation zone; separating the mixture in the second separation zone into a second heavy fraction comprising soluble coal products, some deashing solvent and some process solvent and a second light fraction comprising deashing solvent and some process solvent; withdrawing the second heavy fraction from the second separation zone; withdrawing the second light fraction from the second separation zone; introducing the second light fraction into a third separation zone; separating the second light fraction in the third separation zone into a third heavy fraction comprising process solvent and a third light fraction comprising deashing solvent; withdrawing the third heavy fraction from the third separation zone; withdrawing the third light fraction from the third separation zone; passing at least a portion of the third light fraction to the second mixing zone to aid in providing the feed mixture; introducing the remaining third light fraction into a fourth separation zone; introducing the second heavy fraction withdrawn from the second separation zone into the fourth separation zone; separating the second heavy fraction and third light fraction in the fourth separation zone into a fourth heavy fraction comprising soluble coal products and some deashing solvent and a fourth light fraction comprising deashing solvent and some process solvent; withdrawing the fourth heavy fraction from the fourth separation zone; withdrawing the fourth light fraction from the fourth separation zone; and passing at least a portion of the fourth light fraction withdrawn from the fourth separation zone into the third mixing zone to mix with the first light fraction contained therein.

Claim 9

The process of claim 6 defined further to include the step of: maintaining the temperature level in the first separation zone in the range of from about 400 degrees F. to about 620 degrees F. and a pressure level in a range of from about 500 psig to about 1500 psig to effect the separation of the feed mixture.

Claim 10

The process of claim 6 defined further to include the step of: flashing the first heavy fraction in a second flash zone to produce one stream comprising insoluble coal products and one other stream comprising deashing solvent.

Claim 11

The process of claim 6 defined further to include the step of: passing the third heavy fraction, comprising the process solvent, withdrawn from the third separation zone to the first mixing zone to aid in solubilizing the coal.

Claim 12

The process of claim 6 defined further to include the steps of: flashing the fourth heavy fraction withdrawn from the fourth separation zone in a third flash zone to produce one stream comprising soluble coal products and one other stream comprising deashing solvent.

Claim 13

The process of claim 6 defined further to include the step of: maintaining the second separation zone at a temperature level in a range of from about 500 degrees F. to about 900 degrees F. and a pressure level in a range of from about 300 psig to about 1500 psig to effect the separation in the second separation zone.

Claim 14

The process of claim 11 defined further to include the step of: maintaining the third separation zone at an elevated temperature and a pressure level in a range of from atmospheric pressure to about 1500 psig to effect the separation the third separation zone.

Claim 15

The process of claim 11 defined further to include the step of: maintaining the fourth separation zone at a temperature level higher than the temperature level in the second separation zone and a pressure level in a range of from about 300 psig to about 1500 psig to effect the separation in the fourth separation zone.