Solid Catalyst In At Least One Step Patents (Class 208/413)
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Patent number: 9677015Abstract: Systems and methods are provided for processing a heavy oil feed, such as an atmospheric or vacuum resid, using a combination of solvent assisted hydroprocessing and slurry hydroconversion of a heavy oil feed. The systems and methods allow for conversion and desulfurization/denitrogenation of a feed to form fuels and gas oil (or lubricant base oil) boiling range fractions while reducing the portion of the feed that is exposed to the high severity conditions present in slurry hydroconversion.Type: GrantFiled: June 19, 2014Date of Patent: June 13, 2017Assignee: ExxonMobil Research and Engineering CompanyInventors: Himanshu Gupta, Stephen Harold Brown, Federico Barrai, Kirtan Kunjbihari Trivedi
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Patent number: 9605217Abstract: Systems and methods are provided for sequential slurry hydroconversion of heavy oil feedstocks. One or more low pressure slurry hydroconversion stages can be used to perform a majority of the conversion of a heavy oil feedstock. The bottoms from the low pressure stages can then be slurry hydroconverted in one or more high pressure stages to further convert the feedstock.Type: GrantFiled: June 19, 2014Date of Patent: March 28, 2017Assignee: ExxonMobil Research and Engineering CompanyInventors: Ramanathan Sundararaman, Thomas Francis Degnan, Jr., Rustom Merwan Billimoria, Randolph J. Smiley
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Patent number: 9410093Abstract: A process for the production of high yields of high quality products from heavy hydrocarbonaceous feedstock comprising a two-stage, close-coupled process. The first stage comprises a thermo-catalytic zone into which is introduced a mixture comprising the feedstock, coal, a liquid catalyst precursor, and hydrogen. 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.Type: GrantFiled: March 17, 2014Date of Patent: August 9, 2016Assignee: Chevron U.S.A. Inc.Inventors: Dennis R. Cash, Graham J. Forder, David S. Mitchell, Joel W. Rosenthal
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Patent number: 9371492Abstract: Production processes are provided that can include exposing a carbon-based material to liquid media to form hydrocarbon fuel. Waste to fuel conversion processes as well as waste material processing reactors are provided that can be configured to convert waste to fuel. Heat exchangers, power generation processes and combustion turbine exhaust apparatus are also provided. Fuel generation processes and generation systems are provided. Reaction media conduit systems as well as processes for servicing reactant media pumps coupled to both inlet and outlet conduits containing reactant media, are also provided.Type: GrantFiled: May 1, 2012Date of Patent: June 21, 2016Assignee: GPI Patent Holding LLCInventors: Michael P. Spitzauer, James D. Osterloh
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Patent number: 8916043Abstract: A process for the conversion of coal into fuel bases comprises two successive direct liquefaction stages in ebullated bed reactors followed by a fixed bed hydrocracking stage. This process can produce excellent quality fuel bases (kerosene and diesel).Type: GrantFiled: March 17, 2011Date of Patent: December 23, 2014Assignee: IFP Energies NouvellesInventors: Nadege Charon, Hugues Dulot, Alain Quignard, Wilfried Weiss
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Patent number: 8524073Abstract: Disclosed herein is a sorbent composition including an adsorbent support; and a metal component comprising a transition metal, wherein the metal component is impregnated on a surface of the adsorbent support; and wherein the metal component effects the removal of sulfur and vanadium from a hydrocarbon fuel. Also disclosed herein is a sorbent composition comprising an adsorbent support, wherein a surface of the adsorbent support has been chemically modified to comprise functional groups; and wherein the adsorbent support effects the removal of sulfur and vanadium from a hydrocarbon fuel.Type: GrantFiled: March 23, 2009Date of Patent: September 3, 2013Assignee: General Electric CompanyInventors: John Aibangbee Osaheni, Thomas Joseph Fyvie, Gregory Allen O'Neil, Deborah Ann Haitko, Grigorii Lev Soloveichik, Paul Burchell Glaser
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Publication number: 20130146508Abstract: The invention relates to a process for coal conversion, optionally in co-processing with other feedstocks, notably of the biomass type, comprising at least one liquefaction step, followed by a fixed-bed hydrocracking step and a catalytic reforming step. With this process, aromatic compounds can be obtained from a feedstock containing coal.Type: ApplicationFiled: December 6, 2012Publication date: June 13, 2013Applicant: IFP ENERGIES NOUVELLESInventor: IFP Energies Nouvelles
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Patent number: 8226821Abstract: 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.Type: GrantFiled: August 19, 2009Date of Patent: July 24, 2012Inventors: James B MacArthur, John E Duddy
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Publication number: 20120036764Abstract: A process for converting carbon material into fuel bases comprising two liquefaction stages in the presence of hydrogen in a boiling-bed reactor containing a supported catalyst and integrating a hydrogen production stage generated by non-fossil sources that do not emit CO2. The hydrogen production stage comprises the gasification of biomass and/or the decomposition of water, hydrochloric acid, hydrogen chloride or hydrogen sulfide by thermal, electrolytic, chemical or biological processes. The thus produced hydrogen is sent into at least one of the liquefaction stages.Type: ApplicationFiled: July 19, 2011Publication date: February 16, 2012Applicant: IFP Energies nouvellesInventors: Celine BABE, Raphael Huyghe, Alain Quignard, Wilfried Weiss
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Patent number: 8092672Abstract: A method and apparatus for catalytic hydroconversion processing of less volatile carbonaceous material to volatile liquid products is disclosed. The process is carried out in a plug-flow reactor system using nanosize metallic catalyst particles dispersed in the reactant slurry with compressed hydrogen/hydrogen-sulfide at a temperature between about 275° C. and 525° C. at a pressure of between about 800 psi and 6000 psi and a residence time in the reactors between about 1 minute and 4 hours.Type: GrantFiled: April 11, 2008Date of Patent: January 10, 2012Assignee: Energy Catalysis IncorporatedInventors: Partha S. Ganguli, Alfred G. Comolli
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Publication number: 20110230688Abstract: A process for the conversion of coal into fuel bases comprises two successive direct liquefaction stages in ebullated bed reactors followed by a fixed bed hydrocracking stage. This process can produce excellent quality fuel bases (kerosene and diesel).Type: ApplicationFiled: March 17, 2011Publication date: September 22, 2011Applicant: IFP Energies nouvellesInventors: Nadege CHARON, Hugues Dulot, Alain Quignard, Wilfried Weiss
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Patent number: 7901569Abstract: Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil, hydrogen, and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is separated internally, within one of more of the reactors, to separate only the converted oil and hydrogen into a vapor product while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor as a liquid product. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons in the next reactor, once again creating a mixture of unconverted oil, hydrogen, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: GrantFiled: September 17, 2008Date of Patent: March 8, 2011Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, James Murphy, Bruce Reynolds
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Publication number: 20100219104Abstract: The present invention relates to an integrated process for the conversion of feedstocks containing coal into liquid products by jointly using at least the following seven process units: coal liquefaction, flash or distillation of the product obtained from the liquefaction, extraction with a solvent to remove the ashes, distillation to separate the solvent, hydroconversion with catalysts in slurry phase, distillation or flash of the production obtained from the hydroconversion, and deasphalting with a solvent.Type: ApplicationFiled: March 1, 2010Publication date: September 2, 2010Applicants: ENI S.p.A., SNAMPROGETTI S.p.A, ENITECNOLOGIE S.p.AInventors: Alberto Del Bianco, Romolo Montanari, Nicoletta Panariti, Sergio Rosi
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Publication number: 20090045103Abstract: A process for thermally upgrading coal in a vertical processor wherein the coal is gravity fed and a heated inert gas is introduced into the processor. The temperature of the gas, the size of the coal and the rate of movement of the coal are controlled to efficiently remove moisture from the coal and to not remove volatile organic compound.Type: ApplicationFiled: January 11, 2007Publication date: February 19, 2009Inventors: Harry E. Bonner, Roger B. Malmquist, Ray W. Sheldon
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Patent number: 7431831Abstract: A new residuum full hydroconversion slurry reactor system has been developed that allows the catalyst, unconverted oil, products and hydrogen to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor. In the next reactor, a portion of the unconverted oil is converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor. The slurry reactor system is, in this invention, preceded by an in-line pretreating step, such as hydrotreating or deasphalting.Type: GrantFiled: December 16, 2005Date of Patent: October 7, 2008Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, Bruce Reynolds
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Patent number: 7390398Abstract: Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen gas, while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. Additional oil may be added at the interstage feed inlet, possibly in combination with slurry. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: GrantFiled: December 16, 2005Date of Patent: June 24, 2008Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, Bruce Reynolds
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Patent number: 7247235Abstract: A process for the hydrogenation of a hydrocarbon feed includes contacting a major amount of the hydrocarbon feed with hydrogen in a counter-current manner in a first reaction zone under hydrogenation reaction conditions in the presence of a hydrogenation catalyst in at least a first catalyst bed wherein a liquid effluent exits at a bottom end of the first reaction zone and a hydrogen-containing gaseous effluent exits at a top end of the first reaction zone, and contacting a minor portion of the hydrocarbon feed with said hydrogen-containing gaseous effluent in a co-current manner in a second reaction zone having a catalyst bed positioned to receive the hydrogen-containing effluent of the first reaction zone.Type: GrantFiled: May 30, 2003Date of Patent: July 24, 2007Assignee: ABB Lummus Global Inc,Inventors: Harjeet Virdi, Arup Roy, Thu-Huong Nguyen
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Patent number: 6190542Abstract: A multi-stage catalytic hydrogenation and hydroconversion process for heavy hydrocarbon feed materials such as coal, heavy petroleum fractions, and plastic waste materials. In the process, the feedstock is reacted in a first-stage, back-mixed catalytic reactor with a highly dispersed iron-based catalyst having a powder, gel or liquid form. The reactor effluent is pressure-reduced, vapors and light distillate fractions are removed overhead, and the heavier liquid fraction is fed to a second stage back-mixed catalytic reactor. The first and second stage catalytic reactors are operated at 700-850° F. temperature, 1000-3500 psig hydrogen partial pressure and 20-80 lb./hr per ft3 reactor space velocity. The vapor and light distillates liquid fractions removed from both the first and second stage reactor effluent streams are combined and passed to an in-line, fixed-bed catalytic hydrotreater for heteroatom removal and for producing high quality naphtha and mid-distillate or a full-range distillate product.Type: GrantFiled: February 1, 1999Date of Patent: February 20, 2001Assignee: Hydrocarbon Technologies, Inc.Inventors: Alfred G. Comolli, Lap-Keung Lee
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Patent number: 5269910Abstract: A method for hydro-liquefying coal, the method comprising preheating a slurried mixture of a pulverized coal and a solvent, the preheated mixture being supplied to a plurality of reactors; separating a gaseous content from the products resulting from the reaction; dehydrating the gaseous content and removing a light oil content therefrom, thereby obtaining hydrogen-content gases; and recycling the hydrogen-content gases at least to the first reactor and supplying it to the bottom thereof so that the light oil content in the solvent is stripped.Type: GrantFiled: September 28, 1990Date of Patent: December 14, 1993Assignees: Kabushiki Kaisha Kobe Seiko Sho, Mitsubishi Kasei Corporation, Idemitsu Kosan Company Limited, Cosmo Oil Co., Ltd., Nippon Brown Coal Liquefaction Co., Ltd.Inventors: Tetsuo Matsumura, Kaizaburo Saito, Osamu Okuma, Hiroshi Yoshimura, Yasuo Sugino, Shun-ichi Yanai, Tatsuo Hirano, Kazuhiro Mae, Koji Murakoshi
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Patent number: 5246570Abstract: A coal liquefaction process employing a first stage liquefaction step catalyzed by a soluble molybdenum-containing organophosphorodithioate catalyst is disclosed. In some embodiments, two consecutive liquefaction steps employ a molybdenum-containing organophosphorodithioate catalyst operating at a relatively high liquefaction temperature. In other embodiments, a second liquefaction process step operating at a relatively low temperature employs a hydrocracking catalyst to upgrade materials obtained from the first soluble catalyst liquefaction step. In some embodiments, an interstage gas separator removes gases such as carbon dioxide produced in the first liquefaction step from a partially liquefied mixture prior to further liquefying the mixture in the second liquefaction step.Type: GrantFiled: April 9, 1992Date of Patent: September 21, 1993Assignee: Amoco CorporationInventors: Donald C. Cronauer, April J. Swanson, Joseph T. Joseph, Arunabha Basu, Simon G. Kukes
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Patent number: 5200063Abstract: This invention is directed to a staged process for producing liquids from coal or similar carbonaceous feeds combining a pretreatment stage and a liquefaction stage. In the process, the feed is dispersed in an organic solvent and reacted with carbon monoxide at an elevated temperature and pressure. The so pretreated coal is sent to a liquefaction reactor, wherein the coal is reacted in the presence of hydrogen and catalyst to produce valuable liquid fuels or feedstocks.Type: GrantFiled: October 9, 1991Date of Patent: April 6, 1993Assignee: Exxon Research and Engineering CompanyInventors: Dan R. Neskora, Stephen N. Vaughn, W. Neal Mitchell, Calude C. Culross, Steve D. Reynolds, Edward Effron
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Patent number: 5130013Abstract: A process for producing a liquefied coal oil by a two step hydrogenation reaction of coal, which comprises subjecting coal to a first hydrogenation and subjecting at least a part of the reaction product of the first hydrogenation to a second hydrogenation, wherein the second hydrogenation is conducted in the presence of an alkali metal compound and/or an alkaline earth metal compound and a catalyst carrying a metal of Group VI-A and a metal of Group VIII of the Periodic Table.Type: GrantFiled: October 9, 1990Date of Patent: July 14, 1992Assignees: Mitsubishi Kasei Corporation, Kabushiki Kaisha Kobe Seiko Sho, Idemitsu Kosan Company Limited, Cosmo Oil Co., Ltd.Inventors: Yoichi Kageyama, Iwao Yamamoto, Takahisa Yamaura, Jun Imai
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Patent number: 5122260Abstract: In the two stage liquefaction of a carbonaceous solid such as coal wherein coal is liquefied in a first stage in the presence of a liquefaction solvent and the first stage effluent is hydrogenated in the presence of a supported hydrogenation catalyst in a second stage, catalyst which has been previously employed in the second stage and comminuted to a particle size distribution equivalent to 100% passing through U.S. 100 Mesh, is passed to the first stage to improve the overall operation.Type: GrantFiled: January 9, 1989Date of Patent: June 16, 1992Assignee: ABB Lummus Crest Inc.Inventors: Avinash Gupta, Marvin I. Greene
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Patent number: 5120429Abstract: In a process for producing distillates from coal by a first stage thermal liquefaction followed by a catalytic hydrogenation, liquefaction solvent is added at points spaced over the length of the thermal liquefaction heater.Coal may be co-processed with petroleum oil by adding pre-hydrogenated oil to the first stage or unhydrogenated oil to the second stage.Type: GrantFiled: July 10, 1987Date of Patent: June 9, 1992Assignee: Lummus Crest Inc.Inventors: Avinash Gupta, Marvin I. Greene
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Patent number: 5110451Abstract: A two stage coal extracting process has a first liquid hydrogen donor solvent oil extraction stage and a second stage comprising catalytic hydrocracking of the extract. Desired levels of hydrocracking and hydrogenation of the extract, with an acceptable level of napthene formation, are achieved by using on the catalyst a mixture of a promoted W or Mo catalyst with an unpromoted W or Mo catalyst.Type: GrantFiled: January 16, 1991Date of Patent: May 5, 1992Assignee: Coal Industry (Patents) LimitedInventor: Michael A. Jones
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Patent number: 5110450Abstract: An improved process for the hydroconversion of coal, wherein coal is slurried in an organic solvent and subjected to pretreatment with carbon monoxide, followed by separation of a solvent-soluble phase comprising hydrocarbon material from the coal, and subsequently hydroconverting the extracted material in a hydroconversion reactor. The extracted material consists of a relatively hydrogen-rich material which is readily hydroconverted to valuable liquid products in high yield. The coal residue is relatively hydrogen deficient material which can be gasified to produce hydrogen and carbon monoxide for the hydroconversion and pretreatment stages, respectively.Type: GrantFiled: December 21, 1989Date of Patent: May 5, 1992Assignee: Exxon Research and Engineering CompanyInventors: Claude C. Culross, Steve D. Reynolds
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Patent number: 5096569Abstract: Disclosed is a method for catalytically hydropyrolyzing carbonaceous material to produce liquid products boiling under about 550.degree. C. with reduced amounts of methane being formed. The process comprises (a) treating the carbonaceous material with as hydrogenation catalyst; (b) contacting the so-treated carbonaceous material with an effective amount of hydrogen, at an effective residence time, at a temperature below the critical temperature of rapid methane formation; (c) recovering the resulting liquids, gases, and char; and (d) recycling the char.Type: GrantFiled: January 15, 1991Date of Patent: March 17, 1992Assignee: Exxon Research and Engineering CompanyInventors: Peter S. Maa, Russell R. Chianelli
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Patent number: 5071540Abstract: An improved process for the hydroconversion of coal comprising pretreating coal in an aqeuous carbon monoxide-containing environment, followed by extracting a soluble hydrocarbon material from the coal, and subsequently hydroconverting the extracted material in a hydroconversion reactor with a high catalyst loading to obtain a nearly finished product with low heteroatom levels. The extracted material consists of a relatively hydrogen-rich material which is readily converted to valuable liquid products in high yield. The residue from the extraction stage is relatively hydrogen deficient material which can be gasified to produce hydrogen and carbon monoxide for the hydroconversion and pretreatment stages, respectively.Type: GrantFiled: December 21, 1989Date of Patent: December 10, 1991Assignee: Exxon Research & Engineering CompanyInventors: Claude C. Culross, Steve D. Reynolds
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Patent number: 5055181Abstract: Disclosed is a process for obtaining liquids and gases from carbonaceous material, such as coal. The carbonaceous material is first treated with a gasification catalyst, and optionally a hydrogenation catalyst, and hydropyrolyzed for an effective residence time, below the critical temperature at which methane begins to rapidly form, to make liquid products. The resulting char is gasified in the presence of steam at a temperature from about 500.degree. C. to about 900.degree. C.Type: GrantFiled: December 14, 1988Date of Patent: October 8, 1991Assignee: Exxon Research and Engineering CompanyInventors: Peter S. Maa, Martin L. Gorbaty
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Patent number: 5045180Abstract: 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.Type: GrantFiled: April 16, 1990Date of Patent: September 3, 1991Assignee: HRI, Inc.Inventor: Alfred G. Comolli
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Patent number: 5026475Abstract: An improved process for the hydroconversion of coal comprising pretreating coal in an aqueous carbon monoxide-containing environment, followed by extracting a soluble hydrocarbon material from the coal, and subsequently hydroconverting the extracted material in a hydroconversion reactor. The extracted material consists of a relatively hydrogen-rich material which is readily converted to valuable liquid products in high yield. The residue from the extraction stage is relatively hydrogen deficient material which can be gasified to produce hydrogen and carbon monoxide for the hydroconversion and pretreatment stages, respectively.Type: GrantFiled: December 21, 1989Date of Patent: June 25, 1991Assignee: Exxon Research & Engineering CompanyInventors: Gordon F. Stuntz, Claude C. Culross, Steve D. Reynolds
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Patent number: 4983279Abstract: A process for the hydrogenation of a liquid hydrocarbon-containing charge material, comprising the steps of: (i) supplying a high temperature high pressure liquid phase hydrogenation reactor with two separately and indirectly heated charge streams, (a) a primary charge stream comprising liquid hydrocarbon oils, oil residues, syncrudes, tars or pitches and optionally coal, and hydrogen-containing gas, and (b) a directly heated secondary gaseous charge stream comprising hydrogen-containing gas, and combining said indirectly heated primary charge stream and said indirectly and directly heated secondary charge stream prior to said liquid phase hydrogenation reactor, hydrogenating the combined streams to produce a hydrogenation product and separating the hydrogenation product in a hot separator to give a hot separator head product; wherein said indirectly heated primary and secondary charge streams are heated by separate heat exchange means by heat exchange with said hot separator head product, and said secondaryType: GrantFiled: December 2, 1988Date of Patent: January 8, 1991Assignee: Veba Oel AktiengesellschaftInventors: Wolfdieter Klein, Claus Strecker, Alfons Feuchthofen, Ulrich Boenisch
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Patent number: 4982027Abstract: This invention relates to an improved process for the reprocessing of carbon containing wastes by pretreating the same thermally in the presence or absence of hydrogen, followed by hydrogenation of the pretreated material at elevated temperature and at least 200 bar hydrogen pressure.Type: GrantFiled: January 26, 1989Date of Patent: January 1, 1991Assignee: Rheinische Braunkohlenwerke AGInventors: Joachim Korff, Axel Giehr, Karl-Heinz Keim, Kurt Erdt
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Patent number: 4944866Abstract: 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.Type: GrantFiled: April 15, 1986Date of Patent: July 31, 1990Assignee: Veba Oel Technologie GmbHInventors: Klaus Fuhrmann, Ulrich Graeser, Ludwig Merz
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Patent number: 4879021Abstract: 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.Type: GrantFiled: August 26, 1988Date of Patent: November 7, 1989Assignee: HRI, Inc.Inventors: Edwin J. Hippo, Alfred G. Comolli, Robert O'Brien
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Patent number: 4874506Abstract: 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.Type: GrantFiled: October 16, 1987Date of Patent: October 17, 1989Assignee: HRI, Inc.Inventors: James B. MacArthur, Alfred G. Comolli, Joseph B. McLean
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Patent number: 4853111Abstract: 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.Type: GrantFiled: July 25, 1986Date of Patent: August 1, 1989Assignee: HRI, Inc.Inventors: James B. MacArthur, Joseph B. McLean, Alfred G. Comolli
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Patent number: 4842719Abstract: 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.Type: GrantFiled: June 18, 1986Date of Patent: June 27, 1989Assignee: HRI, Inc.Inventors: James B. MacArthur, Joseph B. McLean, Alfred G. Comolli
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Patent number: 4839030Abstract: 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.Type: GrantFiled: May 27, 1988Date of Patent: June 13, 1989Assignee: HRI, Inc.Inventors: Alfred G. Comolli, Joseph B. McLean
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Patent number: 4818374Abstract: A process for converting coal to an oil fraction, which comprises subjecting coal to a first hydrogenation reaction, deashing the reaction product of the first hydrogenation reaction and subjecting the deashed liquefied oil to a second hydrogenation reaction, wherein coal, a solvent and hydrogenation-treated heavy oil components are supplied for the first hydrogenation reaction; from the first hydrogenation reaction product, at least a part of the oil fraction is obtained; from the first hydrogenation reaction product, a substantial amount of preasphaltene components is removed simultaneously with or independently of the deashing operation, and the deashed liquefied oil containing heavy oil components and not greater than 20% by weight of preasphaltene components thereby obtained, is supplied for the second hydrogenation reaction; from the second hydrogenation reaction product, an oil fraction and heavy oil components are separated and the heavy oil components are recycled to the first hydrogenation reactionType: GrantFiled: November 8, 1985Date of Patent: April 4, 1989Assignees: Mitsubishi Chemical Industries Ltd., Kabushiki Kaisha Kobe Seiko Sho, Idemitsu Kosan Company Limited, Asia Oil Company Limited, Nippon Brown Coal Liquefaction Co., Ltd.Inventors: Nobuyoshi Hirokoh, Yoichi Kageyama, Yukio Nakako, Tetsuo Matsumura
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Patent number: 4816141Abstract: 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.Type: GrantFiled: October 16, 1987Date of Patent: March 28, 1989Assignee: HRI, Inc.Inventors: Joseph B. McLean, Alfred G. Comolli, James B. MacArthur
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Patent number: 4741822Abstract: Procedure for hydrogenation of coal by means of liquid phase and fixed-bed catalyst hydrogenation whereby the head products of the high-temperature separator are led directly, and together with the entire high-pressure circuit gas, over a reactor with a rigidly installed catalyst; are separated from the exhaust products of this reactor by partial condensation of the cycle oil required for producing the coal paste and withdrawn from an intermediate separator; and are led again, together with the entire high-pressure circuit gas, over an additional reactor with a fixed-bed catalyst.Type: GrantFiled: July 29, 1986Date of Patent: May 3, 1988Assignee: Ruhrkohle AktiengesellschaftInventors: Eckard Wolowski, Rainer Loring, Frank Friedrich, Bernd Strobel
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Patent number: 4740289Abstract: A process for the hydrogenolysis of a coal liquid bottom containing benzene-insoluble components and having a boiling point of at least 420.degree. C., which comprises:(a) hydrogenating the coal liquid bottom at a temperature of not higher than 350.degree. C. in the presence of a catalyst comprising an alkali metal and/or an alkaline earth metal and a metal of Group VI A of the Periodic Table to reduce the content of the benzene-insoluble components in the fraction having a boiling point of at least 420.degree. C., to a level of not higher than 10% by weight, and then(b) subjecting the product to hydrogenolysis at a temperature of higher than 350.degree. C. and not higher than 450.degree. C. in the presence of a catalyst comprising a metal of Group VI A of the Periodic Table.Type: GrantFiled: April 20, 1987Date of Patent: April 26, 1988Assignees: Mitsubishi Chemical Industries Ltd., Kabushiki Kaisha Kobe Seiko Sho, Idemitsu Kosan Company Limited, Asia Oil Company, Nippon Brown Coal Liquefaction Co., Ltd.Inventors: Yoichi Kageyama, Tetsuo Masuyama
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Patent number: 4740294Abstract: A method for sequentially co-processing heavy hydrocarbon materials and carbonaceous materials comprising first subjecting the heavy hydrocarbon material in the presence of a disposable metal catalyst to produce and separate therefrom a first distillate stream and a first non-distillable effluent stream containing the disposable metal catalyst. The first non-distillable effluent stream then is mixed with the carbonaceous material and the mixture subjected to liquefaction conditions in the presence of said disposable metal catalyst. The liquefaction product then is subjected through the use of sequential fractionation and critical solvent extraction processing steps to separate and recover various heavy hydrocarbon and carbonaceous-derived light hydrocarbon liquid products therefrom.Type: GrantFiled: September 25, 1984Date of Patent: April 26, 1988Assignee: Kerr-McGee CorporationInventor: Donald E. Rhodes
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Patent number: 4728418Abstract: A novel process for the low-temperature depolymerization and liquefaction of coal wherein the coal is subjected to sequential processing steps for the cleavage of different types of intercluster lnikages during each processing step. A metal chloride catalyst is intercalated in finely crushed coal and the coal is partially depolymerized under mild hydrotreating conditions during the first processing step. In the second processing step the product from the first step is subjected to base-catalyzed depolymerization with an alcoholic solution of an alkali hydroxide, yielding an almost fully depolymerized coal, which is then hydroprocessed with a sulfided cobalt molybdenum catalyst in a third processing step to obtain a hydrocarbon oil as the final product.Type: GrantFiled: October 23, 1985Date of Patent: March 1, 1988Assignee: University of UtahInventors: Joseph S. Shabtai, Ikuo Saito
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Patent number: 4714543Abstract: A starting slurry composed of raw brown coal and a solvent is heated and pressurized, subjected to gas-liquid separation and dehydration and then to hydrogenation/liquefaction. The CO.sub.2 -containing gas produced in the preheating/dehydration step and/or a CO.sub.2 -containing gas supplied from outside the system is blown into the slurry in the above-mentioned preheating/dehydration step, whereby carbonate-forming metal components in the brown coal are converted to the carbonates thereof in advance. In this manner, the hydrogenation/liquefaction efficiency is improved, and stabilized long-term continuous operation is attained.Type: GrantFiled: February 4, 1986Date of Patent: December 22, 1987Assignees: Kabushiki Kaisha Kobe Seiko Sho, Idemitsukosan Kabushiki Kaisha, Mitsubishikaseikogyo Kabushiki Kaisha, Aziasekiyu Kabushiki KaishaInventors: Tetsuo Matsumura, Toshio Ohzawa, Akihiro Kawashima, Osamu Ohkuma, Saburo Sawada, Shun'ichi Yanai, Hiroshi Yoshimura, Yasuo Sugino
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Patent number: 4666589Abstract: A method for pretreating a coal hydrogenation feedstock with preheated hydrogen containing a hydrogenation gas under high pressure and at elevated temperature, in a liquid phase slurry system, is disclosed. In this process a mixture of a slurry of finely ground coal and a slurry oil are fed to a preheater before being subjected to a hydrogenation and liquefaction reaction in a cascade of reactors at a pressure of from 100 to 40 bars and a temperature of 420.degree. to 490.degree. C. The reaction products are fed to a hot separator.In the process of the invention, prior to its preheating, a first partial stream of the hydrogenation gas, referred to as the slurry gas, is added to the mixture at process pressure. A second partial stream of the hydrogenation gas is heated by indirect heat exchange with a gaseous hot separator product in a gas heat exchanger.Type: GrantFiled: February 18, 1986Date of Patent: May 19, 1987Assignee: Veba Oel Entwicklungs-Gesellschaft mbHInventors: Wolf-Dieter Klein, Alfons Feuchthofen, Claus Strecker, Ulrich Bonisch
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Patent number: 4661237Abstract: A process for thermally cracking carbonaceous substances, such as coal, is described, comprising: rapidly heating the carbonaceous substance to 500.degree. to 950.degree. C. in an atmosphere consisting essentially of hydrogen gas at a pressure of 35 to 250 kg/cm.sup.2 (gauge pressure) in the presence of at least one compound selected from the group consisting of halides, sulfates, nitrates, phosphates, carbonates, hydroxides, and oxides of Group VIII metal elements of the Periodic Table. The process increases the cracking of the carbonaceous substances and accelerates the conversion of the carbonaceous substances into gas and liquid products, greatly increasing the yields of the gasoline fraction and light oils.Type: GrantFiled: March 29, 1983Date of Patent: April 28, 1987Assignee: Asahi Kasei Kogyo Kabushiki KaishaInventors: Muneaki Kimura, Tadashi Kai
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Patent number: 4639310Abstract: A process for the production of reformer feed and heating or diesel oil from coal which comprises introducing a pulverized coal-oil slurry together with a hydrogenation gas into a liquid-phase hydrogenation stage; remoping solids-containing residue from the discharge from the liquid phase hydrogenation stage, cooling the resulting residue-free volatile coal-oil fraction from the discharge and, if necessary, removing a slurry oil fraction therefrom before feeding the volatile coal-oil fraction to a gas-phase hydrogenation stage; introducing fresh hydrogen which is substantially free of contaminants into the gas-phase hydrogenation stage together with the volatile coal-oil fraction, the fresh hydrogen introduced into the gas-phase hydrogenation stage constituting the entire amount of hydrogen required for the process; and utilizing the waste-gas from the gas-phase hydrogenation as the hydrogenation gas for the liquid-phase hydrogenation.Type: GrantFiled: August 2, 1985Date of Patent: January 27, 1987Assignee: Veba Oel Entwicklungs-GesellschaftInventors: Werner Dohler, Ludwig Merz, Heinz Frohnert, Bernd Uckermann, Ulrich Graeser, Alfons Jankowski, Eckard Wolowski, Hans-Friedrich Tamm, Norbert Wilczok
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Patent number: 4599161Abstract: 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.Type: GrantFiled: November 30, 1984Date of Patent: July 8, 1986Assignee: Phillips Petroleum CompanyInventors: James Scinta, Arlo J. Moffat