US4379744A
Expired / Lapsed
US
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Coal liquefaction process
Assignee: Chevron USA Inc
•
Filing: 1981-09-08
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Granted: 1983-04-12
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Expires: 2001-09-08
Abstract
Abstract This invention is a process for liquefying coal in at least two stages, comprising (a) heating a slurry comprising a solid particulate coal, and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first reaction zone to substantially dissolve the coal and provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dispersed dissolution catalyst; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dispersed dissolution catalyst with hydrogen in a second reaction zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion. Preferably, the dispersed dissolution catalyst in the first hydrogenation zone is added as an emulsion of aqueous soluble compounds of transition elements, e.g. from Groups IV-B, V-B, VI-B or Group VIII of the Periodic Table.
Inventors
- 👤 Joel W. Rosenthal
- 👤 Arthur J. Dahlberg
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 17:23
CPC Classifications
C; C10; C10G; C10G1/00; C10G1/002; C10G47/00; Y; Y10; Y10S; Y10S208/00; Y10S208/951
Claims Analysis
Total Claims: 45
Claim 1
Independent Claim
126 words
A process for liquefying coal which comprises: (a) heating a slurry comprising a solvent, particulate coal, and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first reaction zone to substantially dissolve the coal and provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dissolution catalyst; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dissolution catalyst with hydrogen in a second reaction zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion.
Claim 2
Dependent Claim
126 words
A process for liquefying coal which comprises: (a) heating a slurry comprising a solvent, particulate coal, and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first reaction zone to substantially dissolve the coal and provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dissolution catalyst; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dissolution catalyst with hydrogen in a second reaction zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion.
Claim 3
Dependent Claim
27 words
A process according to claim 1 wherein said dispersed dissolution catalyst contains a catalytic element selected from the group consisting of lead, tin, and transition metal elements.
Claim 4
Dependent Claim
25 words
A process according to claim 1 wherein said dispersed dissolution catalyst is selected from the group of alkali metal or ammonium molybdates, vanadates, or tungstates.
Claim 5
Dependent Claim
21 words
A process according to claim 2 wherein said dispersed dissolution catalyst is added as an oil-soluble compound of said catalytic element.
Claim 6
Dependent Claim
23 words
A process according to claim 2 wherein said dispersed dissolution catalyst is added as a particulate metal or compound of said catalytic element.
Claim 7
Dependent Claim
25 words
A process according to claim 2 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of a water-soluble compound of said catalytic element.
Claim 8
Dependent Claim
30 words
A process according to claim 1 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of a compound selected from the group of ammonium molybdates and ammonium tungstates.
Claim 9
Dependent Claim
20 words
A process according to claim 1 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of ammonium molybdate.
Claim 10
Dependent Claim
45 words
A process according to claim 4, 5, or 6 wherein the second hydrogenation catalyst is present in a packed bed and said portion of said normally liquid portion of said first effluent slurry is passed upwardly through the packed bed in said second reaction zone.
Claim 11
Dependent Claim
37 words
A process according to claim 9 wherein said second reaction zone is operated at a temperature below about 800° F., a pressure from 1000 to 3000 psig, and a slurry hourly space velocity of 0.1 to 2.
Claim 12
Dependent Claim
29 words
A process according to claim 9 wherein said second hydrogenation catalyst comprises at least one hydrogenation component selected from Group VI-B and Group VIII, supported on an alumina support.
Claim 13
Dependent Claim
21 words
A process according to claim 9 wherein said coal contains less than about 1% by weight iron on a moisture-free basis.
Claim 14
Dependent Claim
21 words
A process according to claim 9 wherein said coal contains more than about 0.5% by weight calcium on a moisture-free basis.
Claim 15
Dependent Claim
12 words
A process according to claim 13 wherein said coal is subbituminous coal.
Claim 16
Dependent Claim
175 words
A process for liquefying coal which comprises: (a) heating a slurry comprising a solvent, particulate coal and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first reaction zone to substantially dissolve the coal and provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dissolution catalyst; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dissolution catalyst with hydrogen in a second reaction zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion; and (c) separating at least a portion of the insoluble solids from said normally liquid portion of said second effluent slurry to produce a solids-lean carbonaceous liquid containing non-distillable liquid components, and recycling at least a portion of the solids-lean carbonaceous liquid containing non-distillable liquid components to step (a).
Claim 17
Dependent Claim
175 words
A process for liquefying coal which comprises: (a) heating a slurry comprising a solvent, particulate coal and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first reaction zone to substantially dissolve the coal and provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dissolution catalyst; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dissolution catalyst with hydrogen in a second reaction zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion; and (c) separating at least a portion of the insoluble solids from said normally liquid portion of said second effluent slurry to produce a solids-lean carbonaceous liquid containing non-distillable liquid components, and recycling at least a portion of the solids-lean carbonaceous liquid containing non-distillable liquid components to step (a).
Claim 18
Dependent Claim
27 words
A process according to claim 15 wherein said dispersed dissolution catalyst contains a catalytic element selected from the group consisting of lead, tin, and transition metal elements.
Claim 19
Dependent Claim
25 words
A process according to claim 15 wherein said dispersed dissolution catalyst is selected from the group of alkali metal or ammonium molybdates, vanadates, or tungstates.
Claim 20
Dependent Claim
21 words
A process according to claim 16 wherein said dispersed dissolution catalyst is added as an oil-soluble compound of said catalytic element.
Claim 21
Dependent Claim
23 words
A process according to claim 16 wherein said dispersed dissolution catalyst is added as a particulate metal or compound of said catalytic element.
Claim 22
Dependent Claim
25 words
A process according to claim 16 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of a water-soluble compound of said catalytic element.
Claim 23
Dependent Claim
30 words
A process according to claim 20 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of a compound selected from the group of ammonium molybdates and ammonium tungstates.
Claim 24
Dependent Claim
20 words
A process according to claim 20 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of ammonium molybdate.
Claim 25
Dependent Claim
45 words
A process according to claim 18, 19, or 20 wherein the second hydrogenation catalyst is present in a packed bed and said portion of said normally liquid portion of said first effluent slurry is passed upwardly through the packed bed in said second reaction zone.
Claim 26
Dependent Claim
37 words
A process according to claim 23 wherein said second reaction zone is operated at a temperature below about 800° F., a pressure from 1000 to 3000 psig, and a slurry hourly space velocity of 0.1 to 2.
Claim 27
Dependent Claim
29 words
A process according to claim 23 wherein said second hydrogenation catalyst comprises at least one hydrogenation component selected from Group VI-B and Group VIII, supported on an alumina support.
Claim 28
Dependent Claim
21 words
A process according to claim 23 wherein said coal contains less than about 1% by weight iron on a moisture-free basis.
Claim 29
Dependent Claim
21 words
A process according to claim 23 wherein said coal contains more than about 0.5% by weight calcium on a moisture-free basis.
Claim 30
Dependent Claim
139 words
A process for liquefying coal which comprises: (a) heating a slurry comprising a solvent, particulate coal, and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first hydrogenation zone to substantially dissolve the coal and to provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dissolution catalyst, said solvent being selected from the group of petroleum and petroleum-derived solvents; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dissolution catalyst with hydrogen in a second hydrogenation zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion.
Claim 31
Dependent Claim
139 words
A process for liquefying coal which comprises: (a) heating a slurry comprising a solvent, particulate coal, and an externally supplied dispersed dissolution catalyst in the presence of hydrogen in a first hydrogenation zone to substantially dissolve the coal and to provide a first effluent slurry having a normally liquid portion comprising solvent and dissolved coal and containing undissolved solids and dissolution catalyst, said solvent being selected from the group of petroleum and petroleum-derived solvents; and (b) contacting at least a portion of said normally liquid portion containing undissolved solids and dissolution catalyst with hydrogen in a second hydrogenation zone in the presence of a second externally supplied hydrogenation catalyst under hydrogenation conditions, including a temperature lower than the temperature to which said slurry is heated in step (a), to produce a second effluent slurry having a normally liquid portion.
Claim 32
Dependent Claim
16 words
A process according to claim 28 wherein said solvent is a petroleum-derived solvent containing metals contaminants.
Claim 33
Dependent Claim
27 words
A process according to claim 28 wherein said dispersed dissolution catalyst contains a catalytic component selected from the group consisting of lead, tin, and transition metal elements.
Claim 34
Dependent Claim
21 words
A process according to claim 30 wherein said dispersed dissolution catalyst is added as an oil-soluble compound of said catalytic element.
Claim 35
Dependent Claim
23 words
A process according to claim 30 wherein said dispersed dissolution catalyst is added as a particulate metal or compound of said catalytic element.
Claim 36
Dependent Claim
25 words
A process according to claim 30 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of a water-soluble compound of said catalytic element.
Claim 37
Dependent Claim
25 words
A process according to claim 28 wherein said dispersed dissolution catalyst is selected from the group of alkali metal or ammonium molybdates, vanadates, or tungstates.
Claim 38
Dependent Claim
30 words
A process according to claim 33 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of a compound selected from the group of ammonium molybdates, or ammonium tungstates.
Claim 39
Dependent Claim
20 words
A process according to claim 33 wherein said dispersed dissolution catalyst is added as an aqueous-oil emulsion of ammonium molybdate.
Claim 40
Dependent Claim
45 words
A process according to claim 31, 32, or 33 wherein the second hydrogenation catalyst is present in a packed bed and said portion of said normally liquid portion of said first effluent slurry is passed upwardly through the packed bed in said second reaction zone.
Claim 41
Dependent Claim
37 words
A process according to claim 37 wherein said second reaction zone is operated at a temperature below about 800° F., a pressure from 1000 to 3000 psig, and a slurry hourly space velocity of 0.1 to 2.
Claim 42
Dependent Claim
29 words
A process according to claim 37 wherein said second hydrogenation catalyst comprises at least one hydrogenation component selected from Group VI-B and Group VIII supported on an alumina support.
Claim 43
Dependent Claim
50 words
A process according to claim 37 further comprising separating at least a portion of the insoluble solids from said second effluent slurry to produce a solids-lean carbonaceous liquid containing non-distillable liquid components and recycling at least a portion of the solids-lean carbonaceous liquid containing non-distillable liquid components to step (a).
Claim 44
Dependent Claim
21 words
A process according to claim 37 wherein said coal contains less than about 1% by weight iron on a moisture-free basis.
Claim 45
Dependent Claim
21 words
A process according to claim 37 wherein said coal contains more than about 0.5% by weight calcium on a moisture-free basis.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-04-11 | 1986-10-11 | 1987-04-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-04-11 | 1990-10-11 | 1991-04-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-04-11 | 1994-10-11 | 1995-04-12 | $7700.00 | Window Closed / Lapsed |