Abstract: Coal hydrogenation processes which produce a residual fraction containing carbonaceous material and ash as well as the desired hydrocarbon product fractions are improved by introducing the residual fraction into an oxidation reactor operating under tangential gas velocities and at a temperature in excess of that of the fusion temperature of the ash. Molten ash drips from the side walls of the reactor and hot hydrogen containing gases are generated for use in the hydrogenation process.

Abstract: Coal hydrogenation catalyst is recovered from coal hydrogenation residues containing carbonaceous matter, coal ash and catalyst by contacting such residues with oxygen and steam under conditions to provide H.sub.2 and CO containing gases and fused ash which contains catalyst, contacting the fused ash with a reactant which will react with the catalyst to form a catalyst compound which is volatile at the temperature of the fused ash and withdrawing vaporized catalyst compound from the fused ash. The vaporized catalyst may be condensed and dissolved in a solvent liquid to form a solution of catalyst for application to coal to be hydrogenated.

Abstract: The sulfur content of solid carbonaceous material, such as coal or lignite, is reduced by feeding said material under recycle gas pressure into a continuous closed pressurized cyclic system operating in the range of about 5 to 30 atmospheres, contacting the coal in a desulfurization zone of the cyclic system with hot hydrogen-containing gases at about 1600.degree. F, removing the desulfurized coal from the resulting gas stream, removing sulfur compounds from the gas stream, and burning a part of the resulting gas stream to supply the hot hydrogen-containing gases for contacting the coal. Hydrogen necessary for the recycle gas stream is generated from the coal in the desulfurization zone. The only input to the system is coal and oxygen. Desulfurized coal, sulfur and excess gases are removed as products.

Abstract: Low sulfur metallurgical coke and pitch and low sulfur, ash-free carbon suitable for electrodes are produced from sulfur-containing, non-coking or coking coals by hydrogenation of such coals in an economical cyclic system in which particulate coal, in the absence of pasting oils, is contacted with a large volume of circulating hydrogen under conditions providing a low sulfur heavy oil or oil-carbonaceous solid mixture which is then converted into the coke, pitch and/or electrode carbon. Sulfur in the coal is converted to gaseous compounds and is removed from the circulating hydrogen stream. Light oils of aromatic nature are also produced.

Abstract: A low sulfur content, heavy oil is produced from coal by direct hydrogenation at a temperature of about 820.degree. to 1000.degree.F and pressure of about 500 to 4000 psi in a pressurized closed cyclic system through which hydrogen is circulated. Coal, oxygen and steam are fed into the pressurized system and the heavy oil of low sulfur content is removed as the product. The pressurized system includes a gas reforming zone, in which hydrocarbon gases produced in the system are reformed with steam and oxygen to provide all or part of the hydrogen requirements of the process, and a coal hydrogenation zone which receives hydrogen-containing gases from the gas reforming zone along with pulverized coal from a pressure feeder.

Abstract: Hydrocarbon oils and gases of high Btu content are produced from coal in a pressurized closed cyclic system through which hydrogen is recycled. Coal, oxygen and steam are fed into the pressurized system and oil and high Btu gas are removed as products. The system includes a coal gasification zone and coal and tar hydrogenation zones which receive hydrogen-containing gases from the coal gasification zone along with recycle hydrogen. The product oil is separated from the combined effluent of the hydrogenation zones and the resulting gases are then purified and separated into product hydrocarbon gases and recycle hydrogen without substantial reduction in system pressure.