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Amoco Liquefies Coal with Methanol and Lye

United States Patent: 5266189

 

In multiple reports, we've thoroughly documented that both Coal and Carbon Dioxide can be converted into Methanol.

Some recent examples of such include: Exxon Coal to Methanol | Research & Development | News; "US Patent 4,348,487 - Production of Methanol via Catalytic Coal Gasification; 1982; Assignee: Exxon Research and Engineering Company, NJ"; and, ConocoPhillips CO2 to Methanol | Research & Development | News; "US Patent Application 20030060355 - Converting CO2 to Oxygenates; 2003; Assignee (presumed): ConocoPhillips".

Herein, from yet another US Oil industry stalwart, we see that, in confirmation of yet other earlier reports, once we have Methanol, whether synthesized from Carbon Dioxide or from Coal, we can use that Methanol to improve the conversion, into liquid hydrocarbons, of more Coal.

 

Comment, with some additional emphases, follows excerpts from:

 

"United States Patent 5,266,189 - Integrated Low Severity Alcohol-Base Coal Liquefaction Process

 

Date: November, 1993

 

Inventor: Joseph T. Joseph, et. al., Illinois

 

Assignee: Amoco Corporation

 

Abstract: An improved, low severity coal liquefaction process is disclosed. In accordance with the process, coal is first decarboxylated and demineralized with hot sulfurous acid. The decarboxylated coal is then liquefied in the presence of an alcohol and an alkali metal hydroxide. In several embodiments, alkali metal-containing materials are reclaimed to produce alkali metal hydroxide for the liquefaction step. In other embodiments, the liquefaction is conducted in the presence of a relatively high-boiling diluent such as a coal-derived liquid.

Claims: A low severity liquefaction process comprising the steps of: reacting a solid carbonaceous material and sulfurous acid ... to decarboxylate the solid material and dissolve minerals present in the solid material; and, liquefying the decarboxylated solid ... in the presence of at least one alkali metal hydroxide and at least one alcohol having one to four carbon atoms to produce a hydrocarbon-containing liquid.

(And) wherein the alcohol is methanol and the alkali metal hydroxide is sodium hydroxide.

A low severity coal liquefaction process comprising the steps of: reacting coal and sulfurous acid ... to decarboxylate and demineralize the coal; recovering the decarboxylated, demineralized coal from a solution containing dissolved coal minerals; and liquefying the decarboxylated coal in the presence of methanol and sodium hydroxide ...  to produce a coal-derived liquid.

(And, further) separating methanol from the coal-derived liquid; (and) reusing the separated methanol as a reactant in the liquefying step; 

(And) separating a sodium-containing sludge from the coal derived-liquid; heating the sludge to burn carbonaceous material contained therein and to convert sodium-containing compounds contained therein to sodium oxide; leaching the sodium oxide with water to produce heat and recycled sodium hydroxide; and 
using the recycled sodium hydroxide as a reactant in the liquefying step.

Background: One way to reduce the cost of coal-derived liquids is to conduct the liquefaction process at relatively low operating temperatures and pressures and in the presence of a hydrogen donor other than high pressure hydrogen. These processes often can be conducted in relatively inexpensive, low pressure stirred or mixed reactors rather than the ebullated bed reactors typically employed in high pressure hydrogen liquefaction processes. One liquefaction reaction suitable for use in such processes is reacting crushed coal in the presence of an alkali metal base, an alcohol and a catalyst to liquefy the coal and to hydrogenate, and in some cases alkylate, the coal-derived liquids.

Summary: It is an object of the present invention to provide an improved low-severity coal liquefaction process ... ."

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First, it shouldn't be too difficult to make the "sulfurous acid" in which the Coal is "first decarboxylated and demineralized" from raw materials obtained from some of our higher-sulfur Coals.

Second, note that this process actually produces excess Methanol, some of which can be recycled to the initial Coal liquefaction step, if we're not already making all the Methanol we need for such Coal liquefaction from Carbon Dioxide, via the technology disclosed in US Patent Application 20030060355, as above. And, of course, Methanol can be converted into Gasoline via, among at least a few others we will later document, ExxonMobil's "MTG"(r) process.

Third, if a liquid carrier for the raw Coal, a "diluent", is needed, then that, too, can be, as specified herein, a "coal-derived liquid".

Fourth, note, as above, that the needed sodium hydroxide can, as well, be derived as a by-product of the overall Coal conversion system.

Finally, if we do elect to, as above, "in some cases alkylate, the coal-derived liquids", we will, according to the Wikipedia's definition of "alkylate", we submit without linkage, be synthesizing a "premium gasoline blending stock" that "has exceptional antiknock properties and is clean burning".

Is there anything else we want, or need, or could ask, our abundant domestic Coal to do for us?