Abstract: Systems and methods of processing coal to form mesophase pitch include performing a low-severity direct coal liquefaction (LSDCL) process on a coal feedstock to produce a coal tar pitch therefrom. The systems and methods can include contacting coal directly with a catalyst in the presence of a solvent, pressurizing the coal in direct contact with the catalyst in the presence of the solvent to a predetermined pressure of about 1000 psia or less, heating the coal in direct contact with the catalyst in the presence of the solvent to a predetermined temperature of about 380° C. or less, and liquefying the coal to form a coal tar pitch. The coal tar pitch can be thermally treated to a liquid crystal phase exhibiting anisotropic spheres of mesophase and spun to form carbon fibers.

Abstract: Processes and systems for upgrading resid hydrocarbon feeds are disclosed. The process system may operate in two different operating modes, maximum conversion and maximum quality effluent. The process system may be reversibly transitioned between the different operating modes. The system has the ability to reversibly transition between the two modes without shutting down the system or losing production.

Abstract: A method for staged combustion in a combustor assembly includes introducing an oxidant stream and a fuel stream at a first location into a combustion chamber to produce a heated stream. A Liquid water stream and an additional oxidant stream, fuel stream or both are then introduced into the heated stream in at least one location along the heated stream downstream from the first location. The additional oxidant stream, fuel stream or both react in the heated stream to generate additional heat that vaporizes liquid water from the liquid water stream to water vapor.

Abstract: An integrated slurry hydroprocessing and steam pyrolosyis system for the production of olefins and aromatic petrochemicals from a crude oil feedstock is provided. Crude oil, a steam pyrolysis residual liquid fraction and slurry reside are combined and treated in a hydroprocessing zone in the presence of hydrogen under conditions effective to produce an effluent having an increased hydrogen content. The effluent is thermally cracked with steam under conditions effective to produce a mixed product stream and steam pyrolysis residual liquid fraction. The mixed product stream is separated and olefins and aromatics are recovered and hydrogen is purified and recycled.

Abstract: A method of operating a slurry phase apparatus includes feeding one or more gaseous reactants into a slurry body of solid particulate material suspended in a suspension liquid contained inside a vessel. The one or more gaseous reactants are fed into the slurry body through a gas distributor having downward facing gas outlets and are fed towards a fluid impermeable partition spanning across the vessel below the gas distributor. The partition divides the vessel into a slurry volume above the partition and a bottom volume below the partition. A differential pressure is maintained over the partition between predefined limits by manipulating or allowing changes in the pressure in the bottom volume by employing a pressure transfer passage establishing flow or pressure communication between the bottom volume and a head space above the slurry body.

Abstract: A process for the production of high yields of high quality products from heavy hydrocarbonaceous feedstock is provided comprising a two-stage, close-coupled process, wherein the first stage comprises a thermal-catalytic zone into which is introduced a mixture comprising the feedstock, coal, dispersed catalyst, and hydrogen; and the second, close-coupled stage comprises a catalytic-hydrotreating zone into which substantially all the effluent from the first stage is directly passed and processed under hydrotreating conditions.

Abstract: A method of removing fines from a hydrocarbon-containing fluid can include preparing a bed media of particulate earthen material (12). The hydrocarbon-containing fluid having fines therein can be passed through the bed media (12) at a flow rate such that a portion of the fines are retained in the bed media (12) to form a filtered hydrocarbon-containing fluid. The flow rate is sufficient to maintain a wetting film of the hydrocarbon-containing fluid across at least a majority portion of the particulate earthen material which is contacted by the hydrocarbon-containing fluid. The filtered hydrocarbon-containing fluid can be recovered from the bed media (12) via a suitable outlet (16) having substantially reduced or eliminated fines content.

Abstract: A system and process for recovering heat from a bitumen froth treatment plant use a sealed closed-loop heat transfer circuit. The system has a heat removal exchanger associated with the plant and receiving hot froth treatment process stream; heat recovery exchanger; the circuit; and an oil sands process fluid line. The circuit includes piping circulating heat exchange media having uncontaminated and low fouling properties. The piping includes a supply line to the heat removal exchanger and a return line for providing heated media to the recovery exchanger. The circuit has a pump for pressurizing the heat exchange media; a pressure regulator for regulating pressure of the media. The pump and the pressure maintain the media under pressure in liquid phase. The oil sands process fluid is heated producing a cooled media for reuse in the heat removal exchanger. High and low temperature heat removal exchangers can be used.

Abstract: The invention provides an apparatus for comminuting coal or other fuel solids in a shear field, and for optionally coating the solids with catalysts for combustion, liquefaction, and or gasification during the milling process. The apparatus further provides for control of water content in the solids may be controlled before, during and after the milling in order to obtain micronized solids with fine hydration layers. The output fuel solids of the apparatus can burn at low temperatures, avoiding emissions of nitrogen oxides, and they also have improved properties for surfactant-free suspension in either water or oil media, as well as for liquefaction and gasification.

Abstract: A method for the pyrolytic extraction of hydrocarbons such as shale oil from kerogen. Oil shale containing kerogen which has been ground into particulate form, is cascaded downwardly between a plurality of rotating trays within a heated processing chamber. As the hydrocarbons are volatized within the chamber, the volatiles are collected and condensed within a condenser or other suitable recovery apparatus.

Abstract: The invention provides systems and methods for extracting and upgrading heavy hydrocarbons from substrates such as oil sands, oil shales, and tar sands in a unitary operation. The substrate bearing the hydrocarbon is brought into contact with a supercritical or near-supercritical fluid, a source of hydrogen such as hydrogen gas, and a catalyst. The materials are mixed and heated under elevated pressure. As a consequence of the elevated temperature and pressure, upgraded hydrocarbon-containing material is provided in a single or unitary operation. In some embodiments, sonication can be used to improve the upgrading process. Fluids suitable for use in the process include carbon dioxide, hexane, and water. It has been observed that upgrading can occur within periods of time of a few hours.

Abstract: The invention described herein relates to a novel process for reducing the carbon dioxide emissions from a coal and/or biomass liquefaction facility by utilizing a steam methane reformer unit in the complex designed to produce additional hydrogen which can be thereafter utilized in the process, as required for the plant fired heaters (including the SMR furnace), and for the production of plant steam. The plant light ends (C1, C2, etc.), which are normally utilized as fuel gas streams are the primary feeds to the SMR Unit along with the tail gas purge from a gasification complex within the facility.

Abstract: A method and apparatus for the continuous sublimation of a substance includes cascading a material containing a substance capable of sublimation, such as water, between a plurality of trays vertically stacked within a processing zone provided within a processing chamber. A substantially atmospheric environment is maintained within the processing zone at a temperature whereby the substance sublimes forming a sublimate within the environment. The environment containing the sublimate is contacted with a drying agent such as a desiccant to maintain the environment whereby the substance sublimes at substantially atmospheric pressure and at the controlled temperature.

Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.

Abstract: A method for the pyrolytic extraction of hydrocarbons such as shale oil from kerogen. Oil shale containing kerogen which has been ground into particulate form, is cascaded downwardly between a plurality of rotating trays within a heated processing chamber. As the hydrocarbons are volatized within the chamber, the volatiles are collected and condensed within a condenser or other suitable recovery apparatus.

Abstract: A multi-stage catalytic process for the direct liquefaction of coal is utilized with a hydrotreater to first liquefy and subsequently treat the product in one integrated process. A fresh hydrogenation catalyst is used to reduce heteroatoms (S, N) from coal liquids in the downstream hydrotreater. This catalyst is then cascaded and re-used in the direct coal liquefaction process, first in the low temperature Stage 1, and then re-used in the high temperature Stage 2. Coal liquid products have very low contaminants and can be readily used to produce gasoline and diesel fuel. Catalyst requirements are substantially lowered utilizing this novel process.

Abstract: A system for producing petroleum products from oil shale includes one or plural kiln lines made up of plural series-connected, indirect-fired, inclined rotary kilns. Plural kiln lines are operated for parallel processing. Oil shale is advanced through kilns in succession and exhausted from each kiln line substantially free of hydrocarbons. Successive kilns along the advancement of oil shale are maintained at successively higher temperatures. A fuel distinct from hydrocarbons in oil shale, such as syngas from a gasifier or hydrogen gas from a separator, drives pyrolysis to extract hydrocarbons. A refining unit located proximate to the kiln lines upgrades extracted hydrocarbons into petroleum products and separates the petroleum products by criteria. A heat extraction unit recovers heat from exhausted oil shale for reuse in kilns. A method involves drying oil shale followed by heating dry oil shale in successively hotter pyrolysis environments.

Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed; In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.

Abstract: A system for producing petroleum products from oil shale includes one or plural kiln lines made up of plural series-connected, indirect-fired, inclined rotary kilns. Plural kiln lines are operated for parallel processing. Oil shale is advanced through kilns in succession and exhausted from each kiln line substantially free of hydrocarbons. Successive kilns along the advancement of oil shale are maintained at successively higher temperatures. A fuel distinct from hydrocarbons in oil shale, such as syngas from a gasifier or hydrogen gas from a separator, drives pyrolysis to extract hydrocarbons. A refining unit located proximate to the kiln lines upgrades extracted hydrocarbons into petroleum products and separates the petroleum products by criteria. A heat extraction unit recovers heat from exhausted oil shale for reuse in kilns. A method involves drying oil shale followed by heating dry oil shale in successively hotter pyrolysis environments.

Abstract: The invention concerns a method for energy conversion of solid fuels in particular containing carbon comprising a first step which consists in reacting said fuels in a first energy conversion reactor (2, 20). The invention is characterized in that it comprises a second step which consists in injecting oxygen brought to the output of said reactor (2, 20), the reaction of the first step being carried out in at least a circulating fluidized bed (30, 31, 40) and in that the metal oxides circulate between two interconnected circulating fluidized beds (30, 31, 40) converting the fuel and oxidizing the oxides.

Abstract: The present invention relates to an automated continuous haulage apparatus and method designed for use in underground environments. Each mobile bridge carrier (10) contains distance measurement (70) and angular position (74) means for determining the mobile bridge carrier's (10) position and the angular position of attached piggyback conveyors (30). Means for determining the ceiling height (76) are utilized to adjust the height of the piggyback conveyors (30). On each mobile bridge carrier (10), input from the various sensors is received by an electronic controller (80) that calculates the position and orientation of the bridge carrier (10) and attached piggyback conveyors (30). The controller then plans an optimal path of movement for the bridge carrier (10) and computes the rate of movement for each independently operated track assembly on the bridge carrier such that the bridge carrier (10) and piggyback conveyors (30) arrive as close as possible to the planned path.

Abstract: A screen assembly for a vibratory separator which, in at least certain aspects, has supporting apparatus with a plurality of openings therethrough, screening material on the supporting apparatus over the plurality of openings, the supporting apparatus recovered from a predecessor screen assembly by applying heat to the predecessor screen assembly, the predecessor screen assembly having the supporting apparatus and predecessor screening material secured to the supporting apparatus by securing material, the heat applied to the predecessor screen assembly sufficient to degrade, powderize, turn to ash and/or cook off the securing material so that recovery of the supporting apparatus is facilitated; and methods for effecting such recovery.

Abstract: Process and apparatus for extraction of oil and hydrocarbons from crushed hydrocarbonaceous solids, such as oil shale, involving the pyrolyzing of the crushed solids with liquid hydrocarbon and syn gas rich in hydrogen and carbon dioxide. Crushed hydrocarbonaceous solids are treated with liquid hydrocarbon and hot syn gas at an elevated temperature in a rotary kiln where the crushed solids are cascaded into the hot syn gas for sufficient time to strip the volatile liquids and gases found in the solids, removing the vaporized liquids, enriched syn gas and spent crushed solids from the kiln, fractionating the vaporized liquids and enriched syn gas into the desired fractions. The enriched syn gas is particularly suited for use in combined-cycle electricity generation and in the preparation of various by-products. The process efficiently recycles heat and energy to reduce harmful atmospheric emissions and reliance on external energy sources.

Abstract: Disclosed is a method of estimating the outflow amount for each component of the effluent of a coal liquefying reactor consisting of vessel type reactors (16a, 16b, 16c) operated under a high temperature and a high pressure. The outflow amount for each component of the effluent is assumed, and the gas-liquid equilibrium composition of the mixture of the composition within the reaction vessel is calculated. Further, the volume flow rates of the gaseous phase and the liquid phase within the reaction vessel are calculated, and the residence time (&tgr;1G, &tgr;2G, &tgr;3G), (&tgr;1S, &tgr;2S, &tgr;3S) of each of the gaseous phase and the liquid phase is calculated on the basis of the gas hold-up within the reaction vessel calculated on the basis of the volume flow rate and the empirical formula. The outflow amount for each component of the effluent is calculated on the basis of the residence time (&tgr;1, &tgr;, . . .

Abstract: A process for the reductive hydrogenation of insufficiently hydrogenated, non-volatile carbonaceous materials to produce vaporizable products wherein the feed materials are brought into initial solution under pressure 300-500.degree. C. with or without the addition of recycle solvent with or without added catalyst. The catalyst may, as an option, be added during agglomeration, if that technique is used, as an oily precursor or as a slurry of a somewhat hydrophobic {namosize} nanosize particulate catalyst or catalyst precursor. Short-contact-time reactors providing plug-type flow and high shear are used. The resultant ashy slurry is passed, highly dispersed, into a fluidized or moving bed of solids that may be inert or catalytic at 350-500.degree. C. and 100-3500 psi where a reducing gas passing up through the bed reductively increases the volatility and decreases the molecular weight of the feed in what is the equivalent of reaction of the feed on each particle in an extremely piston flow manner.

Abstract: A method of coal liquefaction comprising the steps of: (a) producing a coal slurry from a pulverized coal and a solvent; (b) compressing a coke oven gas to prepare a compressed gas; (c) reacting the coal slurry with the compressed gas in a reactor under a high pressure and high temperature condition to form a liquefied product; (d) separating the liquefied product into a used gas and a liquefied slurry; and (e) distillating the liquefied slurry to form a liquefied oil and a solvent refined coal.

Abstract: A process and apparatus for carrying out reactions at elevated temperatures and pressures which minimizes the heat-up and cool-down times by rapid transport of the reactants using pressurized gas through a preheater to a preheated reactor, agitating the reaction mixture and discharging the reactants with high pressure gas through a precooler.

Abstract: Coal is heated between about 95.degree. and 250.degree. C. to evaporate moisture, but not volatile hydrocarbons. The dried coal is heated to a temperature between about 400.degree. and 700.degree. C. to recover volatile hydrocarbons and to form char, the char is treated with hydrogen at a temperature between about 700.degree. and 1000.degree. C. to form methane, and the methane is decomposed to form pure carbon and hydrogen, which is recycled to treat the char.

Abstract: A method of processing hydrocarbon substances including coal, heavy crude oil, and bitumen by hydrogenating the hydrocarbon substance with a gas containing from 20%-100% hydrogen at a pressure in the range of from 50 bar to 700 bar and at a temperature in the range of from 250.degree. C. to 600.degree. C. to produce a hydrogenation residue which is treated in a secondary stripping operation using hydrogen gas at a pressure between about 1.2 bar and 150 bar to recover light hydrocarbon gases from the hydrogenation residue.

Abstract: In a coal liquefaction process an aqueous slurry of coal is prepared containing a dissolved liquefaction catalyst. A small quantity of oil is added to the slurry and then coal-oil agglomerates are prepared by agitation of the slurry at atmospheric pressure. The resulting mixture is drained of excess water and dried at atmospheric pressure leaving catalyst deposited on the agglomerates. The agglomerates then are fed to an extrusion device where they are formed into a continuous ribbon of extrudate and fed into a hydrogenation reactor at elevated pressure and temperature. The catalytic hydrogenation converts the extrudate primarily to liquid hydrocarbons in the reactor. The liquid drained in recovering the agglomerates is recycled.

Abstract: Recycled oil solvents for coal extraction have their content of saturated cyclic species reduced by thermal cracking at 470.degree. to 540.degree. C. for a few minutes, restoring their effectiveness as solvents for coal.

Abstract: A process for the hydrogenation of coal which entails slurrying pulverized coal with oil, hydrogenating the mixture at an elevated temperature and pressure and separating the liquid and solid reaction products from the gaseous reaction products, wherein the slurry oil contains non-process derived hydrocarbon mixtures having a boiling range above about 200.degree. C., in the amount of about 30-100% by weight with the remainder of the slurry oil being process derived oils having a boiling range above about 200.degree. C.

Abstract: Liquid fuel products are produced at least partially from coal by passing into a progressive flow catalytic cracking zone a mixture stream of coal and carbometallic oil, forming mobile hydrogen within said zone under conditions including vapor residence time of up to about 10 seconds, at 900.degree.-1,400.degree. F., and total pressure of about 10 to about 50 pounds per square inch absolute introducing said mobile hydrogen into said mixture stream; contacting said stream with zeolite cracking catalyst to produce liquid products while laying down coke on said catalyst; and separating said coked catalyst from said liquid products.

Abstract: A coal liquefaction process using ionic liquefaction techniques with polar solvent solubilizing agents and water soluble inorganic compounds, produces a carbonaceous liquefaction product which is separated from the process stream by the use of methanol as a partitioning agent and the methanol and solubilizing agent are recovered separately for reuse.

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: Fine particles of solid fossil fuels are pyrolyzed by passage in a thin layer through a heating zone at successively higher temperatures in a non-oxidizing atmosphere while rapidly separating and removing volatile pyrolysis products. The resulting char may be first treated with mineral acid or employed directly in the hydroprocessing of additional solid fossil fuel to liquid fuels. Alternatively, the acid-washed char may be hydrotreated to afford an improved char product having a low sulfur and mineral content.

Abstract: In a coal liquefaction process an aqueous slurry of coal is prepared containing a dissolved liquefaction catalyst. A small quantity of oil is added to the slurry and then coal-oil agglomerates are prepared by agitation of the slurry at atmospheric pressure. The resulting mixture of agglomerates, excess water, dissolved catalyst, and unagglomerated solids is pumped to reaction pressure and then passed through a drainage device where all but a small amount of surface water is removed from the agglomerates. Sufficient catalyst for the reaction is contained in surface water remaining on the agglomerates. The agglomerates fall into the liquefaction reactor countercurrently to a stream of hot gas which is utilized to dry and preheat the agglomerates as well as deposit catalyst on the agglomerates before they enter the reactor where they are converted to primarily liquid products under hydrogen pressure.

Abstract: Process and apparatus for extraction of oil and hydrocarbons from crushed hydrocarbonaceous solids, such as tar sands, involving the pyrolyzing of the said solids with syn gas rich in hydrogen, and preferably syn gas obtained from the gasification of coal. Crushed hydrocarbonaceous solids are treated with hot syn gas containing hydrogen at an elevated temperature in a rotary kiln where the crushed solids are cascaded into the hot syn gas containing hydrogen for sufficient time to strip the volatile liquids and gases found in the said solids, removing the vaporized liquids, enriched syn gas and spent crushed solids from the kiln, fractionating the vaporized liquids and enriched syn gas into desired fractions, and utilizing the enriched syn gas in the preparation of desired by-products. The apparatus includes an improved rotary kiln which speeds the pyrolysis of the crushed solids.

Abstract: A liquefaction process for coal lignite or heavy oil is disclosed utilizing a hydrogen-donor solvent. The preferred hydrogen-donor solvent is recovered as a vapor from the liquefaction mixture. The preferred method for converting the vapor into active hydrogen-donor solvent form involves passage of the vapor over a catalyst bed positioned in the vapor space of the catalyst vessel. Novel apparatus for so positioning the catalyst bed is also disclosed.

Abstract: A practically isothermal temperature distribution of the reactor contents is obtained, especially for high temperature and pressurized hydrogenation reactors operating in the sump-phase by a hydrogenation gas passing over the outer region of the reaction chamber, so that the hydrogenation gas cools the reaction in the chamber. Additionally, the reaction heat which is extracted by the hydrogenation gas is used to heat the reaction components at a stage in the hydrogenation process. The major portion of the reaction heat is used to heat charges, preferably for the reactors, which charges contain no appreciable amounts of solid material. These charges, preferably comprising hydrogenation gas, preferably pass through a jacket space between the reaction chambers and the external portion of the reactors, which external portions preferably make contact with the atmosphere.

Abstract: Method for the production of liquid products, particularly, tar, from organic bulk materials.The invention relates to a method, whereby in an apparatus in one or a multiple of refining stages, organic bulk goods are refined to economically significant base materials, so that they are suitable, either directly or indirectly, for the production of gasifier or diesel fuel.The technical object is to utilize a fluidizing medium, with the help of which it is possible to produce, in a reaction chamber, an increased yield of liquid products, especially tar.According to the invention, the problem is solved by supplying a hydrocarbonaceous gas, especially a gas containing methane and hydrogen, as a fluidizing medium in the individual refining stages, whereby, under the particular refining conditions, there results a decrease of the portion of methane and hydrogen, and a comparative increase of the portion of the liquid product, especially of the portion of tar.

Abstract: Hydrogen sulfide issuing from an oil shale retort is captured in an absorbent bed. When the bed is regenerated as with oxygen containing gas, the sulfur dioxide liberated is reintroduced into the retort for reaction with the spent shale.