Method of refining coal by hydrodisproportionation

Claim 2

An improved method for refining a volatile containing carbonaceous material to produce a slate of hydrocarbon containing co-products by short residence time hydrodiusproportionation comprising the steps of: (a) contacting said carbonaceous material at a volatilization temperature for a time sufficient to volatilize said carbonaceous material, with a hydrogen donor rich gaseous reducing atmosphere which is obtained in substantial part from said carbonaceous material wherein said hydrogen donor rich gaseous atmosphere and said volatilizing temperatures are produced in substantial part in a partial oxidation reaction wherein steam and hydrodisproportionation recycle gas rich in methane and carbon monoxide are reacted with a sub-stoichiometric amount of oxygen, to yield char and hydrocarbon containing vapor; and (b) cooling said vapor to reduce the temperature of said vapor below said volatilization temperature.

Claim 3

The method of claim 1 wherein said co-product slate includes a completely combustible, fluidic slurry fuel system comprising a portion of said char dispersed in an amount of a liquid organic material effective to produce a transportable, liquid/solid mixture, wherein said liquid organic material is at least partially derived from said short residence time hydrodisproportionation, lower chain alcohols and mixtures thereof.

Claim 4

The method of claim 1 wherein said cooling step is effected by direct quench.

Claim 5

The method of claim 2 wherein said lower chain alcohol is derived from the catalyzed reaction in a once-through methanol process utilizing purified hydrodisproportionation hydrocarbon containing vapors.

Claim 6

The method of claim 1 wherein siad hydrodisproportionation is carried out by first subjecting the carbonaceous material to a preconditioning step prior to said hydrodisproportionation.

Claim 7

The method of claim 2 wherein said slurry fuel system further comprises an amount of water effective to form an emulsion for oil-type transport; and, an amount of methanol effective to substantially reduce thermal NO x .

Claim 8

The method of claim 3 wherein said direct quench is effected by utilizing the heavy portion of said hydrogen containing vapor such that said vapor is thermally cracked to lighter hydrocarbon material.

Claim 9

The method of claim 1 wherein said carbonaceous material is coal.

Claim 10

The products produced by the method of claim 2.

Claim 11

An improved method for refining coal to produce a slate of hydrocarbon containing co-products by short residence time hydrodisoproportionation having a thermal efficiency greater than about 75% comprising the steps of: (a) contacting said coal at a volatilization temperature of from about 900° F. to about 1,600° F. at a pressure of from about 100 PSIG to about 1200 PSIG for a time from about 0.2 to about 2 seconds with a hydrogen rich gaseous reducing atmosphere to yield char and hydrocarbon containing vapor wherein the hydrogen to coal ratio is from 0.05 to about 0.25 pounds of hydrogen per one pound of coal, and wherein said hydrogen donor rich gaseous reducing atmosphere is obtained in substantial part from said coal by a partial oxidation reaction wherein steam and hydrodisproportionation recycle gas rich in methane and carbon monoxide are reacted ddwith a sub-stoichiometric amount of oxygen; and cooling said hydrocarbon containing vapor to reduce the temperature of said vapor below said volitilization temperatures by direct quench with a recycle heavy oil stream to a temperature which is approximately 100° F. less than said volatilization temperature, and to a final quench temperature of about 850° F. with recycle water and oil.

Claim 12

An improved method for refining coal to produce a slate of hydrocarbon containing co-products by short residence time hydrodisoproportionation having a thermal efficiency greater than about 75% comprising the steps of: (a) contacting said coal at a volatilization temperature of from about 900° F. to about 1,600° F. at a pressure of from about 100 PSIG to about 1200 PSIG for a time from about 0.2 to about 2 seconds with a hydrogen rich gaseous reducing atmosphere to yield char and hydrocarbon containing vapor wherein the hydrogen to coal ratio is from 0.05 to about 0.25 pounds of hydrogen per one pound of coal, and wherein said hydrogen donor rich gaseous reducing atmosphere is obtained in substantial part from said coal by a partial oxidation reaction wherein steam and hydrodisproportionation recycle gas rich in methane and carbon monoxide are reacted ddwith a sub-stoichiometric amount of oxygen; and cooling said hydrocarbon containing vapor to reduce the temperature of said vapor below said volitilization temperatures by direct quench with a recycle heavy oil stream to a temperature which is approximately 100° F. less than said volatilization temperature, and to a final quench temperature of about 850° F. with recycle water and oil.

Claim 13

The method of claim 10 wherein said co-product slate includes a completely combustible, fluidic slurry fuel system comprising from about 10 weight percent to about 80 weight percent of said char dispersed in an amount of a liquid organic material effective to produce a transportable, liquid/solid mixture, wherein said liquid organic material is at least partially drived from said short resident time hydrodisproportionation, lower chain alcohols and mixtures thereof wherin the Btu content of said fuel system is greater than about 12,000 Btu per pound and the sulfur content of the content of said liquid organic material is less than about 0.15 weight percent and the nitrogen content of said liquid organic material is less than about 0.2 weight percent.

Claim 14

The method of claim 10 wherein said partial oxidation reaction is carried out at tempeatures of from about 1,300° F. to about 3,000° F. and pressures of about 100 PSIG to about 1,200 PSIG with a mole equivalent of oxygen to CH 4 /CO of from about 0.01 to about 1.0.

Claim 15

The method of claim 11 wherein said lower chain alcohol is derived from the catalyzed reaction in a once-through methonal process utilizing purified hydrodisproportionation hydrocarbon containing vapors.

Claim 16

The method of claim 10 wherein said hydrodisproportionation is carried out by first subjecting the coal to a preconditioning step wherein the coal is contacted with CH 4 /CO rich recycle gas at from about 100 PSIG to about 1,200 PSIG at a temperature of from about 800° F. to about 1,050° F. at residence times of from abut 30 seconds t about 3 minutes prior to said hydrodisproportionation.

Claim 17

The method of claim 11 wherein said slurry fuel system further comprises an amount of water effective to form an emulsion wherein the water is the discontinuous phase from about 1 weight percent to about 12 weight percent; and, with sufficient methanol to reduce thermal NO x .

Claim 18

The method of claim 10 wherein as a result of said cooling step said recycle heavy oil is thermallly cracked to lighter hydrocarbon material.

Claim 19

The products produced by the method of claim 10.