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Two-stage co-processing of coal/oil feedstocks

  • US 4,853,111 A
  • Filed: 07/25/1986
  • Issued: 08/01/1989
  • Est. Priority Date: 04/22/1985
  • Status: Expired due to Term
First Claim
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1. A two-stage continuous process for catalytic hydroconversion of a fluid blend of a solid carbonaceous material and heavy hydrocarbon liquid, comprising:

  • (a) mixing a solid carbonaceous particulate material with sufficient heavy hydrocarbon liquid having at least about 90 V% normally boiling above 650°

    F. to provide a flowable slurry mixture, the total hydrocarbon liquid/coal feed weight ratio being between about 1.0/1 and 3/1 with the solid carbonaceous material being between about 25 and 50 W% of the total feed material;

    (b) feeding the flowable slurry mixture with hydrogen into a first stage back-mixed catalytic reaction zone containing an ebullated catalyst bed of particulate hydrogenation catalyst, said reaction zone having an internal liquid recycle;

    said catalyst containing an active metal component wherein the metal in said component is selected from the metals group consisting of cobalt, iron, molybdenum, nickel, tin, tungsten, and mixtures thereof on a support material, said catalyst bed being maintained at 650°

    -800°

    F. temperature, 1000-4000 psig hydrogen partial pressure and feed rate of 10-100 lb carbonaceous material plus heavy hydrocarbon liquid feed per hour per ft3 reaction zone volume for hydrogenation reaction to partially hydrogenate and hydroconvert the feed materials to hydrocarbon material containing less than 6 W% C1 -C3 hydrocarbon gases, 15-25 W% 650°

    F.- light liquid fraction and 60-70 W% 650°

    F.+ hydrocarbon material fraction;

    (c) passing the total effluent material from said first stage reaction zone with additional hydrogen directly to a close-coupled second stage back-mixed catalytic reaction zone containing an ebullated catalyst bed so as to avoid forming retrograde materials in the effluent, said catalyst containing an active metal component wherein the metal in said component is selected from the metals group consisting of cobalt, iron, molybdenum, nickel, tin, tungsten and mixtures thereof on a support material, said second stage reaction zone being maintained at a higher temperature than the first stage reaction zone, and at 750°

    -900°

    F. temperature and 1000-4000 psig hydrogen partial pressure to convert the remaining unconverted carbonaceous material to hydrocarbon gases, hydrocarbon liquid fraction normally boiling between 400°

    -650°

    F. and including a high boiling residuum fraction;

    (d) passing the resulting effluent material from said second stage reaction zone to successive phase separation and distillation steps to separate the gas material fraction; and

    (e) removing unconverted coal and ash solids material and a heavy hydrocarbon bottoms liquid material, and thereby producing low-boiling hydrocarbon liquid products normally boiling between 150°

    F. and 975°

    F.

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