Two-stage co-processing of coal/oil feedstocks
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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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°-800° F. temperature, 1000-4000 psig hydrogen partial pressure and 10-100 lb/hr/ft3 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°-900° F. temperature for further catalytic; and hydrogenation and hydroconversion reactions. By this process, the blended coal and petroleum feed materials are successively catalytically hydrogenated and hydroconverted at the selected conditions, which results in significantly increased yields of desirable low-boiling hydrocarbon liquid products and minimal production of undesirable residuum and unconverted coal and hydrocarbon gases, while catalyst life is substantially increased.
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Citations
14 Claims
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A two-stage continuous process for catalytic hydroconversion of a fluid blend of sub-bituminous coal and petroleum atmospheric residuum liquid, the process comprising:
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(a) mixing the particulate sub-bituminous coal with sufficient petroleum atmospheric residuum having at least about 90 V% normally boiling above 650°
F. and containing at least about 20 W% aromatic compounds to provide a flowable slurry mixture, the total petroleum residuum/coal feed weight ratio being between 1.0/1 and 3/1, with the coal feed being between about 25 and 50 W % of the total hydrocarbon feed material;(b) feeding the 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 ratio at least about 1;
1, said catalyst containing an active metal component wherein the metal iin said component is selected from the group consisting of cobalt, iron, molybdenum, nickel, tin, tungsten, and combinations thereof deposited on a support material selected from the group consisting of alumina, magnesia, silica, titania and similar materials, said catalyst bed being maintained at 700°
-780°
F. temperature, 1500-3500 psig hydrogen partial pressure and feed rate of 15-75 pound coal plus petroleum residuum oil per hr per ft3 reactor volume for hydrogenation and hydroconversion reactions to provide lower boiling hydrocarbon materials 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 together with additional hydrogen directly to a close-coupled second stage back-mixed catalytic reaction zone so as to avoid forming retrograde materials in the effluent, said catalyst containing an active metal oxide or other metal compound selected from the metals group consisting of cobalt, iron, molybdenum, nickel, tin, tungsten and combinations thereof deposited on a support material selected from the group consisting of alumina, magnesia, silica, titania and similar materials, said second stage zone containing an ebullated catalyst bed maintained at a higher temperature than the first stage reaction zone, and at 780°
-860°
F. temperature, and 1500-3500 psig hydrogen partial pressure to hydroconvert the remaining coal and residuum 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 remove the gas material fraction; and (e) removing unconverted coal and ash solids material and a heavy hydrocarbon bottoms liquid material, recycling a hydrocarbon fraction normally boiling above about 550°
F. to the coal slurrying step, and thereby producing a low-boiling hydrocarbon liquid products normally boiling between 150° and
975°
F.
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14. A two-stage continuous process for catalytic hydroconversion of a fluid blend of a bituminous coal and heavy hydrocarbon liquid, comprising:
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(a) mixing a particulate bituminous coal 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 bituminous coal 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 ratio of at least about 1;
1, said catalyst containing an active metal component wherein the metal in said component is selected from the group consisting of cobalt, iron, molybdenum, nickel, tin, tungsten, and mixtures thereof deposited 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 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 together 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 group consisting of cobalt, iron, molybdenum, nickel, tin, tungsten and mixtures thereof deposited 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 coal to hydrocarbon gases, a 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 liquid bottoms material, recycling a hydrocarbon fraction normally boiling above 550°
F. to the coal slurrying step, and thereby producing low-boiling hydrocarbon liquid products normally boiling between 150°
F. and 975°
F.
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Specification
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Current AssigneeInstitut Francais Du Petrole (IFP Energies Nouvelles)
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Original AssigneeHRI, Inc. (Japan) (Canon Inc.)
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InventorsComolli, Alfred G., MacArthur, James B., McLean, Joseph B.
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Primary Examiner(s)Straub, Gary P.
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Application NumberUS06/889,587Time in Patent Office1,103 DaysField of Search208/413, 208/417, 208/434, 208/59, 208/108US Class Current208/421CPC Class CodesC10G 1/006 Combinations of processes p...
