We have provided several reports on FMC Corporation's government-sponsored development of it's "COED" coal conversion technology, at a plant in Princeton, NJ.
We have also documented Spain's establishment of at least one coal liquefaction facility; and, have noted the reported effectiveness of Koppers-Totzek coal gasification technology.
And, we have delivered evidence that the carbonaceous residue left behind by some primary coal liquefaction processes can itself be further processed, to yield even more useful hydrocarbon liquids and gasses.
Herein, it is documented that coal conversion residue, produced in New Jersey during FMC COED coal liquefaction operations, was shipped to Spain for further processing in a Koppers coal gasifier, with a resultant "conversion of the char (COED residue) to gas" of "85 to 90%".
Though not stated, we'll presume the "gas" to be either synthesis gas, or "SNG" - synthetic natural gas, either being suitable for further catalysis and conversion into liquids; or, direct, industrial use as fuel.
Excerpts:
"Title: Gasification of COED chars in a Koppers--Totzek gasifier. Final report
Author: Brunsvold, N.J.; Wintrell, R.
Publication Date: July 01, 1978
OSTI ID: 6848258; Report Number: EPRI-AF-615; Technical Report
Research Organization: FMC Corp., Princeton, NJ (USA); Koppers Co., Inc., Pittsburgh, PA
Abstract:
In December 1974, EPRI entered into a contract with the FMC Corporation to demonstrate COED char gasification in a commercial Koppers--Totzek gasifier. The chars were shipped to Spain in early 1975 and the gasification tests conducted at the ENFERSA plant in Puentes de Garcia Rodriguez, Spain in August 1975. The results of these tests on the two chars demonstrated that COED char could be gasified in the Koppers--Totzek gasifiers. The useful gas yield was about 45 MSCF of carbon monoxide plus hydrogen gas per ton of char. The carbon conversion of the char to gas was 85 to 90%. Some problems were encountered with the refractory lining on the plant; however, technology is claimed to be available to enable proper refractory selection for commercial life. On the basis of these results, confidence exists for the design of larger (30 tons per hour), more modern Koppers--Totzek gasifiers based on the gasification of COED char. Prior to these tests (and to other tests on the gasification of Coal Liquefaction Residues reported in EPRI Report AF-233) concern was expressed in several quarters that the residues from partial coal conversion processes, such as pyrolysis or coal liquefaction, might be too inactive to enable their conversion to gas in gasification processes. The results of the tests reported here and in AF-233 show that such residues can be converted to synthesis gas at reasonable oxygen consumptions and carbon conversions. Although the development of pyrolysis processes is still being pursued, they do not appear to be as attractive for most potential applications in the power industry as complete conversion processes for reasons which are given. 200 Pages."
Some passages bear repeating, with emphases added:
"Prior to these tests (and to other tests on the gasification of Coal Liquefaction Residues ...) concern was expressed ... that the residues from partial coal conversion ... might be too inactive to enable their conversion to gas ... . The results ... show that ... residues can be converted to synthesis gas ... ."
And:
"On the basis of these results, confidence exists for the design of larger (30 tons per hour), more modern Koppers--Totzek gasifiers based on the gasification of COED char."
Sadly, not enough confidence, it seems, or we would now be liquefying coal and gasifying the coal liquefaction residues. But, in New Jersey and Spain, it's been demonstrated that even the carbonaceous residue left behind by primary coal liquefaction processes can itself be processed, recycled, into even more liquid fuel raw material: "synthesis gas".