Coal liquefaction-gasification process including reforming of naphtha product

Claim 1

A combination coal liquefaction-gasification-naphtha reforming process comprising passing substantially the entire raw mineral-containing feed coal for the process, hydrogen, recycle dissolved liquid solvent, recycle normally solid dissolved coal and recycle mineral residue to a coal liquefaction zone to dissolve hydrocarbonaceous material from mineral residue and to hydrocrack said hydrocarbonaceous material to produce a mixture comprising hydrocarbon gases, naphtha, dissolved liquid boiling above the naphtha boiling range, normally solid dissolved coal and suspended mineral residue; recycling to said liquefaction zone a portion of said dissolved liquid boiling above the naphtha boiling range, normally solid dissolved coal and mineral residue; separating a naphtha fraction; separating distillate liquid boiling above the naphtha range from non-recycled normally solid dissolved coal and mineral residue to produce a gasifier feed slurry; passing a first portion of the total naphtha yield of said process comprising between about 30 and 95 weight percent of the total through a reforming zone comprising heating means, a naphtha hydropretreater and a reformer for conversion to gasoline; said reforming zone producing a first hydrogen-rich stream; returning said first hydrogen-rich stream to said process for use as process hydrogen; passing a second portion of the total naphtha yield comprising between about 5 to 70 weight percent of the total of said process as fuel and burning said second portion of naphtha in said process; said gasifier feed slurry comprising substantially the entire normally solid dissolved coal and mineral residue yield of said liquefaction zone substantially without normally liquid coal and hydrocarbon gases; passing said gasifier feed slurry to a gasification zone; said gasifier feed slurry comprising substantially the entire hydrocarbonaceous feed to said gasification zone; said gasification zone including an oxidation zone for the conversion of hydrocarbonaceous material to synthesis gas; converting a portion of said synthesis gas to a second hydrogen-rich stream; returning said second hydrogen-rich stream to said process for use as process hydrogen; the amount of hydrocarbonaceous material passed to said gasification zone being sufficient to enable said gasification zone to produce an additional amount of synthesis gas beyond the amount required to produce process hydrogen; burning said additional amount of synthesis gas or a CO fraction thereof without hydrogenative upgrading as fuel in said process; and the amount of hydrocarbonaceous material passed to said gasification zone being established so that the thermal efficiency of said process is substantially unaffected by changes in the ratio of said first portion of naphtha to said second portion of naphtha.