Abstract: A carbonaceous feed material, a potassium compound having a relatively poor catalytic activity as compared to that of potassium carbonate, and a sodium or lithium salt are introduced into a gasification reactor. The carbonaceous material is then gasified in the presence of the added potassium and sodium or lithium constituents. The added sodium or lithium salt apparently activates the relatively noncatalytic potassium compound thereby producing a substantial catalytic effect on the gasification reactions. In general, activation of the noncatalytic potassium compound will take place when the sodium or lithium compound introduced into the reactor is either a salt of a weak acid or a salt of a strong acid that is converted to a sodium or lithium salt of a weak acid in the reactor at gasification conditions.

Abstract: Coal or similar liquefiable carbonaceous solids are converted into lower molecular weight liquids by contacting the feed solids with molecular hydrogen in the absence of externally added hydrocarbon liquids under liquefaction conditions during sequential residence in two or more liquefaction zones arranged in series and operated such that the temperature in each zone increases from the first to the final zone. The effluent from each liquefaction zone is passed to the next succeeding higher temperature zone in the series. No hydrocarbon liquids are added to the first zone in the series and the only liquids present in each succeeding zone of the series are the liquids in the effluent from the preceding zone. Liquid hydrocarbonaceous products are recovered from the effluent withdrawn from the last zone.

Abstract: Hydrocarbon liquids and a methane-containing gas are produced from carbonaceous feed solids by contacting the solids with a mixture of gases containing carbon monoxide and hydrogen in a devolatilization zone at a relatively low temperature in the presence of a carbon-alkali metal catalyst. The devolatilization zone effluent is treated to condense out hydrocarbon liquids and at least a portion of the remaining methane-rich gas is steam reformed to produce the carbon monoxide and hydrogen with which the carbonaceous feed solids are contacted in the devolatilization zone. The char produced in the devolatilization zone is reacted with steam in a gasification zone under gasification conditions in the presence of a carbon-alkali metal catalyst and the resultant raw product gas is treated to recover a methane-containing gas.

Abstract: Carbonaceous solids slurried in an aqueous solution, which preferably contains catalyst constituents having gasification activity, are dried by contacting the slurry with superheated steam in a fluid bed slurry dryer and the resultant dried solids are subsequently gasified with steam generated in the dryer.

Abstract: An increased yield of hydrogenated liquid product is obtained from coal by contacting the feed coal with a hydrogen-donor solvent and a hydrogen-containing gas in a series of two or more liquefaction zones arranged in series and operated in such a manner that the temperature in each zone increases from the initial to the final zone. The effluent from each liquefaction zone is passed to the next succeeding higher temperature zone in the series. Liquid hydrocarbonaceous products are recovered from the effluent withdrawn from the last zone. Hydrogen-donor solvent may be produced in the process by catalytically hydrogenating at least a portion of the liquid product from the last liquefaction zone, recovering a liquid fraction from the product of the catalytic hydrogenation and separating a hydrogen-donor solvent from the liquid fraction.

Abstract: Cement is produced by feeding residue solids containing carbonaceous material and ash constituents obtained from converting a carbonaceous feed material into liquids and/or gases into a cement-making zone and burning the carbon in the residue solids to supply at least a portion of the energy required to convert the solids into cement.

Abstract: A tubesheet for supporting closely spaced heat exchange tubes includes a plurality of sleeves or similar tubular members, through which the heat exchange tubes pass, disposed within a frame such that the longitudinal axes of all the tubular members are parallel. Preferably, each tubular member is welded or otherwise attached to the tubular member adjoining it. The frame is comprised of flanges that are normally welded or otherwise attached to the tubular members that adjoin them. The resultant tubesheet is stronger than conventional tubesheets having the same length of bridge wall separating the tube openings and therefore may be used to obtain a smaller than normal spacing between the tubes.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced, alkali metal constituents are recovered from the particles by treating them with a calcium or magnesium-containing compound in the presence of water at a temperature between about 250.degree. F. and about 700.degree. F. and in the presence of an added base to establish a pH during the treatment step that is higher than would otherwise be possible without the addition of the base. During the treating process the relatively high pH facilitates the conversion of water-insoluble alkali metal compounds in the alkali metal residues into water-soluble alkali metal constituents.

Abstract: A high purity chemical synthesis gas is produced by reacting steam with a carbonaceous feed material in the presence of a carbon-alkali metal catalyst and substantially equilibrium quantities of added hydrogen and carbon monoxide at a temperature between about 1000.degree. F. and about 1500.degree. F.

Abstract: An intermediate Btu gas is produced by reacting steam with a carbonaceous feed material in the presence of a carbon-alkali metal catalyst and substantially equilibrium quantities of added hydrogen and carbon monoxide at a temperature between about 1000.degree. F. and about 1500.degree. F. and a pressure in excess of about 100 psia to produce an effluent or raw product gas consisting essentially of equilibrium quantities, at reaction temperature and pressure, of methane, steam, carbon dioxide, carbon monoxide and hydrogen; recovering at least a portion of the effluent or raw product gas from the gasifier as an intermediate Btu product gas; contacting a carbon-containing material with steam in a steam reforming zone under conditions such that at least a portion of the carbon-containing material reacts with the steam to produce carbon monoxide and hydrogen; and passing the effluent from the reforming zone into the gasifier, thereby supplying the added hydrogen and carbon monoxide required in the gasifier.

Abstract: Improved liquid yields are obtained during the hydrogen-donor solvent liquefaction of coal and similar carbonaceous solids by maintaining a higher concentration of material having hydrogenation catalytic activity in the downstream section of the liquefaction reactor system than in the upstream section of the system.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced in the gasifier or similar reaction zone, alkali metal constitutents are recovered from the particles by withdrawing and passing the particles from the reaction zone to an alkali metal recovery zone in the substantial absence of molecular oxygen and treating the particles in the recovery zone with water or an aqueous solution in the substantial absence of molecular oxygen. The solution formed by treating the particles in the recovery zone will contain water-soluble alkali metal constituents and is recycled to the conversion process where the alkali metal constituents serve as at least a portion of the alkali metal constituents which comprise the alkali metal-containing catalyst.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced, alkali metal constituents are recovered for the particles by contacting or washing them with an aqueous solution containing calcium or magnesium ions in an alkali metal recovery zone at a low temperature, preferably below about 249.degree. F. During the washing or leaching process, the calcium or magnesium ions displace alkali metal ions held by ion exchange sites in the particles thereby liberating the ions and producing an aqueous effluent containing alkali metal constituents. The aqueous effluent from the alkali metal recovery zone is then recycled to the conversion process where the alkali metal constituents serve as at least a portion of the alkali metal constituents which comprise the alkali metal-containing catalyst.

Abstract: An increased yield of hydrogenated liquid product is obtained from coal by treating the feed coal with a hydrogen-donor solvent and hydrogen-containing gas in a first coal liquefaction reactor to produce a liquefaction effluent; separating the liquefaction effluent into a vaporous stream and a liquid stream, the liquid stream consisting of a low molecular weight liquid fraction and a high molecular weight liquid fraction; removing a sufficient amount of the low molecular weight liquid fraction from the high molecular weight liquid fraction to form a heavy bottoms stream containing less than about 50 weight percent of the low molecular weight liquid fraction based on the weight of the high molecular weight liquid fraction; treating the heavy bottoms stream with additional fresh hydrogen-donor solvent and hydrogen-containing gas in a second coal liquefaction reactor; separating the second liquefaction reactor product into a vaporous fraction and a liquid fraction, and recovering hydrogenated liquid products fro

Abstract: Sulfonic acids are converted into a hydrocarbon oil of superior oxidation stability by transforming the acids into compounds selected from the group consisting of ammonium sulfonates, substituted ammonium sulfonates, and sulfonic acid esters; and hydrotreating the resultant sulfonic acid derivatives at elevated temperatures in the presence of a hydrotreating catalyst. The hydrotreating process frees the parent hydrocarbons that originally constituted the organic portion of the sulfonic acids by cleaving the carbon-sulfur bond of the sulfonic acid derivatives. These parent hydrocarbons are recovered from the reaction products of the hydrotreating step and comprise a hydrocarbon oil that exhibits a higher stability toward oxidation than can otherwise be obtained from other hydrocarbon oils of similar composition and viscosity.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced, alkali metal constituents are recovered from the particles by treating them with a calcium or magnesium-containing compound in the presence of water. The treating process is carried out under conditions such that the calcium or magnesium-containing compound reacts with water insoluble constituents of the alkali metal residues such as alkali metal aluminosilicates to produce an aqueous solution containing water soluble alkali metal constituents. The aqueous solution is recycled to the gasification process where the alkali metal constituents serve as at least a portion of the alkali metal constituents which comprise the alkali metal-containing catalyst.

Abstract: In a coal gasification operation or similar conversion process carried out in the presence of an alkali metal-containing catalyst wherein solid particles containing alkali metal residues are produced, alkali metal constituents are recovered from the particles primarily in the form of water soluble alkali metal formates by treating the particles with a calcium or magnesium-containing compound in the presence of water at a temperature between about 250.degree. F. and about 700.degree. F. and in the presence of added carbon monoxide. During the treating process the water insoluble alkali metal compounds comprising the insoluble alkali metal residues are converted into water soluble alkali metal formates.

Abstract: The temperature of the reflux fed to a fractionating tower is increased after the reflux enters the tower and before it passes onto the reflux return tray by passing the reflux through an atomizer in the fractionating tower above the reflux return tray to produce a downfalling spray of liquid droplets; collecting the droplets on a reflux pan located between the atomizer and the reflux return tray, the reflux pan being designed to allow the passage of hot vapors rising from the reflux return tray; and passing the collected liquid from the reflux pan onto the reflux return tray. The distance between the reflux pan and the atomizer is such as to allow the downfalling droplets to absorb sufficient heat from the hot rising vapors so that the temperature of the reflux liquid collected on the reflux pan is increased to a desired value.

Abstract: An intermediate Btu gas is produced by reacting steam with a carbonaceous feed material in the presence of a carbon-alkali metal catalyst and substantially equilibrium quantities of added hydrogen and carbon monoxide at a temperature between about 1000.degree. and about 1500.degree. F. and a pressure in excess of about 100 psia to produce a raw product gas consisting essentially of equilibrium quantities, at reaction temperature and pressure, of methane, steam, carbon dioxide, carbon monoxide and hydrogen; withdrawing the raw product gas from the gasifier and treating it for the removal of acid gases to produce a treated gas; withdrawing a portion of the treated gas as an intermediate Btu product gas; mixing the remainder of the treated gas with steam; passing the resultant mixture into a steam reforming furnace where the methane in the gas reacts with the steam to produce additional amounts of carbon monoxide and hydrogen; and passing the effluent from the reforming furnace into the gasifier.

Abstract: Sulfonic acids are converted into a hydrocarbon oil of superior oxidation stability by transforming the acids into compounds selected from the group consisting of ammonium sulfonates, substituted ammonium sulfonates, and sulfonic acid esters; and hydrotreating the resultant sulfonic acid derivatives at elevated temperatures in the presence of a hydrotreating catalyst. The hydrotreating process frees the parent hydrocarbons that originally constituted the organic portion of the sulfonic acids by cleaving the carbon-sulfur bond of the sulfonic acid derivatives. These parent hydrocarbons are recovered from the reaction products of the hydrotreating step and comprise a hydrocarbon oil that exhibits a higher stability toward oxidation than can otherwise be obtained from other hydrocarbon oils of similar composition and viscosity.