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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

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°to about 700°F. and a hydrogen partial pressure of 100 to 2000 psig for a time sufficient to hydrogenate the solid coal particles; and (c) withdrawing the coal/oil slurry having the hydrogenated coal particles from the first reaction zone and passing the coal/oil slurry to a second reaction zone containing a catalytic bed which is maintained at a temperature of between about 700°and about 850°F. and a hydrogen partial pressure of 9 to 2000 psig to liquefy and convert the coal to useful hydrocarbon liquid fuel products. The first and second reaction zones may include the same or different catalysts such as Co/Mo on a porous substrate, or the second reaction zone can include a noble metal such as platinum on a porous substrate such as alumina or silica.

대표청구항 ▼

A continuous two reactor stage coal conversion process for catalytic hydrogenation of coal particles and subsequent liquefaction thereof for producing coal-derived hydro-carbon liquid and gas products, said process comprising: (a) mixing solid coal particles having particle size ranging from about 2

A continuous two reactor stage coal conversion process for catalytic hydrogenation of coal particles and subsequent liquefaction thereof for producing coal-derived hydro-carbon liquid and gas products, said process comprising: (a) mixing solid coal particles having particle size ranging from about 20 mesh to about 400 mesh (U.S. Sieve Series) with hydrocarbon liquid solvent in a solvent/coal weight ratio at least sufficient to provide a flowable coal/oil slurry feed of said solid coal particles, a substantial portion of said hydrocarbon solvent having a normal boiling point ranging from about 400°F. to about 1100°F.; (b) passing said coal/oil slurry and hydrogen upwardly through a first reaction zone containing hydrocarbon solvent liquid which is partly generated from the coal and substantially hydrogenated therein, said first reaction zone containing a catalytic ebullated bed of particulate solid hydrogenation catalyst maintained at a temperature ranging from about 550°F. to about 650°F., and having a hydrogen partial pressure of 100 to 2000 psig for a residence time between about 5 minutes and about 90 minutes to substantially hydrogenate said solvent oil and said solid undissolved coal particles simultaneously in said coal/oil slurry by transfer of gaseous hydrogen to the solvent oil and coal particles without substantial liquefaction of the coal, said catalyst containing an active non-alkali metal or metal compound selected from the group consisting of Co/Mo, Ni/Mo, Li, Sn promoted Co/Mo, W promoted Co/Mo, NiS, CoS, MoS, FeS, FeS2, LiH, MgH2 and mixtures thereof supported on a porous substrate material, said first catalytic ebullated bed reaction zone being back mixed by recycled liquid slurry within the reaction zone; (c) withdrawing said coal/oil slurry effluent containing said hydrogenated coal particles from said first reaction zone and passing said coal/oil slurry through a second reaction zone containing a catalytic ebullated bed of particulate hydrogenation catalyst which is maintained at a temperature between about 700°F. and about 850°F., and a hydrogen partial pressure of 100 to 2000 psig for a residence time of about 1 to 90 minutes to liquefy and convert said hydrogenated coal particles to gas and liquid fractions, said catalyst containing an active non-alkali metal or metal compound supported on a porous substrate material, said second catalytic ebullated bed reaction zone being back mixed by recycled liquid within the reaction zone; (d) passing said gas and liquid fractions from said second reaction zone to a gas-liquid-solids separation zone, from which separation zone a coal-derived hydrocarbon liquid stream containing a reduced solids concentration is recycled directly without further hydrogenation to said coal slurrying step to provide at least part of the hydrocarbon solvent liquid for said coal/oil slurry feed, a recovered hydrogen gas stream is recycled to said first reaction zone to provide the hydrogen partial pressure in the first reaction zone, and a liquid stream is removed containing an increased concentration of insoluble materials and ash; and (e) recovering from said separation zone hydrocarbon liquid distillate and gaseous hydrocarbon products, whereby the substantial catalytic hydrogenation of the coal particles in the first reaction zone before catalytic liquefaction in the second reaction zone provides increased yields of C4-975°F. fraction hydrocarbon liquid products, with the yield of cyclohexane soluble product material being about 60-90 W% of the coal feed.