Abstract: A process for catalytic multi-stage hydrogenation and liquefaction of coal to produce high yields of low-boiling hydrocarbon liquids containing low concentrations of nitogen compounds. First stage catalytic reaction conditions are 700.degree.-800.degree. F. temperature, 1500-3500 psig hydrogen partial pressure, with the space velocity maintained in a critical range of 10-40 lb coal/hr ft.sup.3 catalyst settled volume. The first stage catalyst has 0.3-1.2 cc/gm total pore volume with at least 25% of the pore volume in pores having diameters of 200-2000 Angstroms. Second stage reaction conditions are 760.degree.-870.degree. F. temperature with space velocity exceeding that in the first stage reactor, so as to achieve increased hydrogenation yield of low-boiling hydrocarbon liquid products having at least 75% removal of nitrogen compounds from the coal-derived liquid products.

Abstract: Supported carbon-coated catalyst material and a method for producing and using same in catalytic reaction processes, preferably in ebullated or fluidized catalyst beds. The catalyst materials are prepared by depositing a porous carbon layer on a support material of a selected metal oxide or compound to produce 5-40 wt. % carbon thereon, then preferentially treating the carbon based layer by partial oxidation, pyrolysis or reduction to enhance and activate the carbon layer on the catalyst. Promoter materials can also be advantageously added either to the support material or to the carbon layer in 0.5-10 wt. % to provide an improved composite carbon-coated catalyst having total pore volume of 0.3-1.0 cc/gm, substantially increased surface area of 80-600 M.sup.2 /gm, low surface acidity, particle strength of 1.8-5 lb/mm with reduced particle attrition losses and improved catalyst performance characteristics.

Abstract: A fluidized bed combustion system and method for combusting particulate fuel such as coal together with a sorbent material such as limestone to heat a pressurized liquid and generate saturated vapor, such as steam. The combustion system utilizes at least one concentric dual-sided riser-downcomer unit having a central riser passageway and a concentric outer downcomer passageway located above a dense phase fluidized bed in an enclosure module, the downcomer being configured for directing particulate solids back to the bed. The unit inner and outer passageway surfaces each include a heat exchange panel containing the pressurized liquid for absorbing heat from combustion of the fuel and generating the vapor such as pressurized steam. Primary air is provided below the fluidized bed, while secondary air is provided into the riser passageway.

Abstract: A fluidized bed gas-solids contact reactor, which utilizes at least one capped concentric dual-sided riser-downcomer unit having a central inner riser passageway and a concentric outer downcomer passageway. The riser-downcomer unit is usually located above the fluidized bed, and is adapted for directing the downflowing solids back into the fluidized bed for recycle. The reactor unit inner and outer passageway surfaces include a heat exchange panel having inner and outer channels each containing a circulating liquid. Particulate solids from the dense phase fluidized bed are continuously circulated in dilute phase through the riser-downcomer unit passageways by a reactant gas to exchange heat with the liquid. The particulate solids can be a catalyst or a fuel material. The invention also includes a combustion system and method for combusting a particulate fuel such as coal in air to generate pressurized saturated liquid for producing saturated steam.

Abstract: A process for the hydrogenation of undissolved coal and subsequent liquefaction of the hydrogenated coal particles to provide useful hydrocarbon liquid products including naphtha, gasoline and diesel fuel. These low boiling hydrocarbon liquids are produced by the process comprising: (a) mixing solid coal particles with a coal derived solvent in a solvent/coal ratio ranging from about 8/1 to about 1.5/1 to provide a flowable coal/oil slurry of solid coal particles; (b) passing the coal/oil slurry and hydrogen upwardly through a first reaction zone containing a coal-derived liquid and bed of particulate catalyst maintained at a temperature ranging from about 400.degree. to about 700.degree. F.

Abstract: A process for catalytic two-stage hydrogenation and liquefaction of coal with selective extinction recycle of all heavy liquid fractions boiling above a distillation cut point of about 600.degree.-750.degree. F. to produce increased yields of low-boiling hydrocarbon liquid and gas products. In the process, the particulate coal feed is slurried with a process-derived liquid solvent normally boiling above about 650.degree. F. and fed into a first stage catalytic reaction zone operated at conditions which promote controlled rate liquefaction of the coal, while simultaneously hydrogenating the hydrocarbon recycle oils. The first stage reactor is maintained at 710.degree.-800.degree. F. temperature, 1000-4000 psig hydrogen partial pressure, and 10-90 lb/hr per ft.sup.3 catalyst space velocity. Partially hydrogenated material withdrawn from the first stage reaction zone is passed directly to the second stage catalytic reaction zone maintained at 760.degree.-860.degree. F.

Abstract: Method for treating particulate used oil-coated catalysts to provide a rejuvenated catalyst material in a rejuvention vessel assembly. The pressurizable vertically-oriented vessel assembly has inlet and outlet openings for the catalyst and washing fluids, and has a removable lower sub-assembly head portion which contains a conical shaped grid unit located therein. The vessel assembly is arranged to permit solvent washing, vacuum drying and acid treatment and gas drying of the used catalyst in a bed supported above the conical grid, by upward flow and recycle of the washing liquids and fluidization of the catalyst. Following rejuvenation of the catalyst, it is withdrawn from the vessel downwardly through the conical shaped grid and out through a central withdrawal conduit containing a slide valve unit for further processing or use as desired.

Abstract: A process for two-stage catalytic co-processing of coal and heavy petroleum hydrocarbon liquid fractions to produce increased yields of low-boiling hydrocarbon liquid and gas products. In the process, the particulate coal is slurried with a petroleum residuum and optionally with a process-derived hydrocarbon liquid solvent and fed into a first stage catalytic reaction zone operated at relatively mild conditions which promote controlled rate liquefaction of the coal while simultaneously hydrogenating the petroleum and hydrocarbon recycle oils at conditions favoring hydrogenation reactions. The first stage reactor is maintained at 650.degree.-800.degree. F. temperature, 1000-4000 psig hydrogen partial pressure and 10-100 lb/hr/ft.sup.3 space velocity for the total coal and oil feed. From the first stage reaction zone, the partially hydrogenated effluent material is passed directly to the close-coupled second stage catalytic reaction zone maintained at more severe conditions of 750.degree.-900.degree. F.

Abstract: A process for two-stage catalytic hydrogenation and liquefaction of coal to produce increased yields of low-boiling hydrocarbon liquid and gas products. In the process, the particulate coal is slurried with a process-derived liquid solvent and fed at temperature below about 650.degree. F. into a first stage catalytic reaction zone operated at conditions which promote controlled rate liquefaction of the coal, while simultaneously hydrogenating the hydrocarbon recycle oils at conditions favoring hydrogenation reactions. The first stage reactor is maintained at 650.degree.-800.degree. F. temperature, 1000-4000 psig hydrogen partial pressure, and 10-60 lb coal/hr/ft.sup.3 reactor space velocity. The partially hydrogenated material from the first stage reaction zone is passed directly to the close-coupled second stage catalytic reaction zone maintained at a temperature at least about 25.degree. F. higher than for the first stage reactor and within a range of 750.degree.-875.degree. F.

Abstract: A coal hydrogenation and liquefaction process in which particulate coal feed is pressurized to an intermediate pressure of at least 500 psig and slurried with CO.sub.2 liquid to provide a flowable coal/CO.sub.2 slurry feedstream, which is further pressurized to at least 1000 psig and fed into a catalytic reactor. The coal particle size is 50-375 mesh (U.S. Sieve Series) and provides 50-80 W % coal in the coal/CO.sub.2 slurry feedstream. Catalytic reaction conditions are maintained at 650.degree.-850.degree. F. temperature, 1000-4000 psig hydrogen partial pressure and coal feed rate of 10-100 lb coal/hr ft.sup.3 reactor volume to produce hydrocarbon gas and liquid products. The hydrogen and CO.sub.2 are recovered from the reactor effluent gaseous fraction, hydrogen is recycled to the catalytic reactor, and CO.sub.2 is liquefied and recycled to the coal slurrying step. If desired, two catalytic reaction stages close coupled together in series relation can be used.

Abstract: A multi-stage catalytic process for hydrogenation and liquefaction of coal using ebullated-bed catalytic reactors to produce low-boiling hydrocarbon liquid products, in which used catalyst is removed from a lower temperature first stage reactor operating at temperature not exceeding about 800.degree. F. and cascaded forward to a higher temperature second stage reactor for further use therein. Reaction conditions in the first stage reactor are preferably 700.degree.-800.degree. F. temperature, 1000-4000 psig hydrogen partial pressure, and a coal feed rate of 10-90 lb coal/hr per ft.sup.3 catalyst settled volume in the reactor. Useful higher temperature or second stage reaction conditions are 750.degree.-850.degree. F. temperature, and 1000-4000 psig hydrogen partial pressure.

Abstract: A catalyst rejuvenation vessel assembly for treating particulate used oil-coated catalysts to provide a rejuvenated catalyst material is disclosed. A pressurizable vertically-oriented vessel assembly has inlet and outlet openings for the catalyst and washing fluids, and has a removable lower sub-assembly head portion which contains a conical shaped grid unit located therein. The vessel assembly is arranged to permit solvent washing, vacuum drying and acid treatment and gas drying of the used catalyst in a bed supported above the conical grid, by upward flow and recycle of the washing liquids and fluidization of the catalyst. Following rejuvenation of the catalyst, it is withdrawn form the vessel downwardly through the conical shaped grid and out through a central withdrawal conduit containing a slide valve unit for further processing or use as desired.

Abstract: An improved flow distribution system for a catalytic reactor plenum chamber for a gas-liquid-solids ebullated bed reactor incudes a baffled nozzle device containing at least two baffle plates usually oriented substantially normal to the nozzle inlet flow direction for providing good mixing and uniform flow distribution of gas-liquid materials in the lower portion of the plenum, used in combination with distribution grid to effect a substantially uniform flow distribution of the gas/liquid mixture upwardly into the ebullated catalyst bed. A sparger can be provided in the plenum above the baffled flow distributor device for feeding additional gas-liquid mixture into the reactor. The flow distribution system provides a substantially uniform flow distribution of the gas-liquid mixture into the ebullated bed and thereby provides fouling-free operation of the reactor.

Abstract: Used catalyst containing carbon and sulfur deposits is continuously regenerated by staged burnoff of the carbon and sulfur using a multiple zone treatment vessel containing thin beds of catalyst. The catalyst is exposed to successively increased temperatures and oxygen concentrations to effectively remove substantially all the carbon and sulfur deposits. The used catalyst can be that removed from hydroconversion processes, such as from H-Oil, H-Coal and fluid catalystic cracking processes, and processed in a multizone treatment vessel in combination with proper auxiliary heating equipment for continuous step-wise regeneration of the catalyst. Operating conditions of catalyst temperature, oxygen concentration of gas, and catalyst residence time in each stage of the catalyst regeneration process are carefully controlled to provide staged burnoff of carbon and sulfur deposits for superior regenerated catalyst results.

Abstract: Spent catalysts removed from a catalytic hydrogenation process for hydrocarbon feedstocks, and containing carbon undesired metals contaminants deposits, are rejuvenated for reuse. Following solvent washing to remove process oils, the catalyst is treated either with chemicals which form sulfate or oxysulfate compounds with the metals contaminants, or with acids which remove the metal contaminants, such as 5-50 W % sulfuric acid in aqueous solution and 0-10 W % ammonium ion solutions to substantially remove the metals deposits. The acid treating occurs within the temperature range of 60.degree.-250.degree. F. for 5-120 minutes at substantially atmospheric pressure, after which the rejuvenated catalyst containing carbon deposits can be effectively reused in the catalytic hydrogenation process.

Abstract: A process for improving the upgrading/conversion of hydrocarbonaceous materials such as coals, petroleum residual oils, shale oils and tar sand bitumens. In the process, the free radicals formed from thermal cracking of the hydrocarbons are reacted with the free radicals formed by the thermal cracking of a free radical forming chemical reactant, such as dimethyl ether, to yield stable low molecular weight hydrocarbon distillate products. The hydrocarbonaceous feed material is preheated to a temperature of 600.degree.-700.degree. F. and the hydrocarbon and the free radicals forming chemical, such as dimethyl ether, are passed through a flow reactor at temperature of 750.degree.-900.degree. F., pressure of 200-1000 psi, and liquid hourly space velocity of 0.3 to 5.0 LHSV. Free radicals formed from the hydrocarbon feed material and from the ether material react together in the reactor to produce low molecular weight hydrocarbon liquid materials.

Abstract: An improved process for catalytic desulfurization of petroleum residua feedstocks to provide at least about 75% desulfurization of the liquid product while achieving low catalyst deactivation and increased catalyst age. In the process which uses an ebullated catalyst bed reactor, the reaction conditions are usually maintained at 790.degree.-860.degree. F. temperature, 1000-1800 psig hydrogen partial pressure, and 0.2-2.0 Vf/hr/Vr space velocity. To control carbon and metals deposition on the catalyst, used catalyst is withdrawn from the reactor, a minor portion of the catalyst is discarded to control metals deposition and maintain catalyst activity, and the remaining catalyst is regenerated to remove carbon by carbon burnoff and returned to the reactor for further use. If desired, the regenerated catalyst can be presulfided before returning it to the reactor. Following phase separation and distillation steps, the desulfurized hydrocarbon liquid products are withdrawn from the process.

Abstract: This invention provides a process for producing ethanol from a D-sugar in a continuous aerobic environment using a flocculant respiration-deficient mutant of Saccharomyces uvarum in a single stage fermentor with a cell settling tank and cell recycle, at a productivity of more than 50 grams ethanol per liter fermentor volume per hour. The process comprises (a) innoculating a fermentation zone with a respiration-deficient mutant of Saccharomyces uvarum; (b) feeding a mixture of a D-sugar, a nitrogen source, a vitamin source and a mineral source into the fermentation zone in the presence of oxygen, and (c) fermenting the D-sugar mixture for a sufficiently long period of time to yield an ethanol product. In the process, the yeast are allowed to settle for a sufficiently long period of time and recycled to the fermentation zone to increase ethanol productivity. The preferred D-sugar that may be used in the present process to produce ethanol, is D-glucose.

Abstract: A process for high hydroconversion of petroleum residua containing at least about 25 V % material boiling above 975.degree. F. to produce lower boiling hydrocarbon liquid products and avoid undesirable precipitation of asphaltene compounds. In the process, the feedstock is at least about 80 percent catalytically hydroconverted to material boiling below 975.degree. F. and containing a mixture of gas and liquid fractions, after which the gas fraction is removed while maintaining the resulting liquid fractions temperature above about 730.degree. F. to avoid precipitation of asphaltene compounds which causes operations difficulties in the downstream equipment. Alternatively, the pressure-reduced liquid fraction can be stripped of material boiling below about 650.degree. F. before cooling the liquid to a temperature below about 730.degree. F. to prevent such precipitation of asphaltene compounds in the downstream equipment.

Abstract: Thermal hydrogenation of solids-containing carbonaceous feed materials to produce hydrocarbon gaseous and liquid products is performed in a thermal reaction zone, in which the feed material flows generally downwardly countercurrent to upflowing hydrogen and recycled hydrocarbon liquid. The recycled hydrocarbon liquid is at a rate sufficient to control the settling of solids-containing feed through the reactor, and is obtained from the reaction zone upper end by phase separation from gaseous effluent at reaction conditions. The gaseous effluent material is removed from the thermal reaction zone upper end, and heavy liquid material containing less than about 40 W % solids is withdrawn from the reaction zone bottom end, with both streams being passed to further phase separation and distillation steps for recovery of the hydrocarbon gas and liquid products.