United States Patent: 4183733
Our headline might be a little misleading, since Methane doesn't seem actually to be the end product of the indirect Coal conversion technology described by this United States patent, awarded to a German inventor.
Although the label isn't applied, synthesis gas, "syngas", to be catalyzed into higher hydrocarbons, is.
As we explain following excerpts from:
"United States Patent 4,183,733 - Hydro Gas Plant with Utilization of the Residual Coke
Date: January, 1980
Inventor: Walter Jager, Germany
Abstract: A hydro gas plant with utilization of the residual coke, comprising a gasifier into which raw coal is introduced for hydro gasification that results in the production of methane; a furnace for cracking the methane into hydrogen and carbon monoxide; and means for utilizing the combustion heat of the residual coke obtained during the operation of the gasifier, or a low-BTU gas produced from the coke, in at least the cracking furnace but optionally also in a steam generator. The use of exhaust gases from the cracking furnace is also suggested, namely in a preheater through which hydrogen is fed to the gasifier.
Claims: A hydro gas plant with utilization of residual coke, comprising, in combination: a first gasifier into which raw coal is introduced for hydro gasification that results in the production of a gas including methane with residual coke as a byproduct; a cryogenic separator wherein the gas exiting from said first gasifier is further separated into its constituents, namely methane, carbon monoxide and hydrogen; a furnace for cracking the methane originating from said separator into hydrogen and carbon monoxide with exhaust gases as byproducts; a heat exchanger operatively connected with said furnace for passing the methane to and conversely a cracked gas mixture from said furnace in countercurrent fashion; a second gasifier for producing low-BTU gas from at least a portion of the residual coke derived from said first gasifier; a steam generator for adding steam to the methane before being passed from said separator to said furnace through said heat exchanger; and means for utilizing the combustion heat of at least one of the produced residual coke and low-BTU gas by burning in the processes being conducted in at least one of said furnace and said steam generator."
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We close our excerpts here, since the full patent disclosure is so detailed that schematics would be necessary for a complete understanding.
In essence, they are making synthesis gas, the "hydrogen and carbon monoxide", from which higher hydrocarbons can be produced.
However, they are doing so by incorporating several recycle processes throughout the system, wherein what would otherwise be waste heat and waste products are utilized.
And, one of the otherwise waste products so utilized is the still-carbonaceous residue from the primary Coal gasification.
If you recall previous reports we've made, the FMC Corporation operated, in New Jersey, an indirect Coal conversion plant, under contract to the US Government, where they demonstrated their "COED" technology for the conversion of Coal, via a gasification process, into more versatile hydrocarbons. The carbonaceous residues from that facility were then shipped all the way to Spain for further processing, to yield even more hydrocarbons, in a direct Coal liquefaction process facility there.
All of that is thoroughly documented in the West Virginia Coal Association's R&D archives.
Our take on the German technology disclosed herein, is that they are using both waste heat from the primary Coal gasification process, Steam and a portion of the produced Methane, to "crack", to further convert, for indirect conversion into additional hydrocarbons, the carbonaceous residues left by the primary, or initial, process.
Like much of what we present, the method is so complicated that it begs study by those qualified both to explain it to the rest of us and to help us reduce it to commercial practice.
And, again like much of what we present, we submit it primarily to further demonstrate how refined, how efficient, how highly-evolved and developed the science and technology, for converting our abundant Coal into the hydrocarbon resources we need, has become.
