The United States Patent Application we enclose in this dispatch seems as good a way as any to begin reporting both on a technology for Coal liquefaction that has been established by West Virginia University and one or two of WVU's Coal technology development partners; and, on a business plan that WVU seems to have embarked upon to see that the technology is reduced to actual commercial practice.
We caution in advance, and we will remind you as we go along in coming reports, that WVU's latest suite of Coal conversion technologies represents a definitive advancement over what we have earlier reported as the "West Virginia Process" for the direct liquefaction of Coal; a technique which utilizes the Hydrogen-donor solvent known as "Tetralin", an hydrogenated version of the primary Coal, or Coke oven, oil, "Naphthalene", to effect, under rather extreme conditions of temperature and pressure, the hydrogenation and dissolution of the Carbon in the raw Coal feed.
As we once speculated for you, we believe the West Virginia Process itself to represent an advancement on the much earlier, Nobel Prize-winning Bergius process, about which we've reported, for instance in:
West Virginia Coal Association | Bergius 1928 Coal Liquefaction | Research & Development; concerning: "United States Patent 1,669,439 - Process for Distilling and Liquefying Coal; 1928; Inventor: Friedrich Bergius, of Heidelberg, Germany; Abstract: This invention relates to improvements in a correlated process for distilling and liquefying coal. Process which comprises subjecting coal to distillation treatment whereby there are produced ammonia, coke, tar, a gaseous fraction relatively poor in hydrogen but of high heating value and a gaseous fraction relatively rich in hydrogen, admixing the said tar with coal and subjecting the mixture to liquefaction and hydrogenation treatment with the gaseous fraction relatively rich in hydrogen at elevated temperature and under great pressure whereby there are produced ammonia, oil, and a gas of high heating value, combining the gas of high heating value with said gaseous fraction relatively poor in hydrogen, and separately recovering the said oil"; and, in:
West Virginia Coal Association | CoalTL Wins Nobel Prize - in 1931 | Research & Development; concerning: "The Nobel Prize In Chemistry 1931 Presentation Speech; 'High Pressure Techniques'. The purpose of this work was to resolve a problem which, in importance, can be compared with the nitrogen problem, namely the manufacture of oils and liquid fuels from solid coal ... which is also known as liquefaction of coal. Since the natural stocks of petroleum are fairly restricted, we would sooner or later be faced with the need to restrict the use of oil for the purpose mentioned or even to stop using it altogether, unless methods were available whereby these oil products could be artificially made from other crude materials at an acceptable price.
According to the composition of the coal, it is possible in this way to extract 50 to 70% of the carbon contained in the raw material in the form of oils".
And, which West Virginia Process we've attempted to define and describe in a selection of reports, such as:
West Virginia Coal Association | WVU says Coal Liquids "Greener" than Petroleum | Research & Development; concerning: "'Solvent Extraction Of Low Grade Coals For Clean Liquid Fuels'; (by) Elliot B. Kennel, et. al.; West Virginia University; Abstract: Solvent extraction of bituminous coals has been used as a means of coproducing clean liquid transportation fuels as well as solid fuels for gasification. Coal solvents are created by first hydrogenating coal tar distillate fractions to the level of a fraction of a percent and then simply dissolving the coal in the hydrogenated solvent. Solvent extraction is an evolutionary way by which criteria emissions can be reduced during the production process while replacing processes such as co-production of coal tar from metallurgical grade coke production, as a means of obtaining liquid products from coal. In the case of solvent extraction processes, the present authors advocate the creation of heavy aromatic coal-derived crudes from coal as a simpler and less expensive process than the creation of synthetic sweet light crudes. This process involves dissolving coal in a commodity solvent such as decant oil or coal tar distillate, usually with the addition of hydrogen-rich diluent in order to increase the total solubility of the coal, and to decrease the viscosity. The total amount of hydrogenation in the solution can be as low as a fraction of a percent by mass ... . In this way, it is possible to dissolve up to about 90% of the coal feedstock as determined on a dry ash-free basis".
Note that WVU has increased, through it's improvements on the direct Coal liquefaction technology for producing "clean liquid transportation fuels", the consumption and use of the initial Carbon content in Coal from about "50 to 70%", in the original Bergius process, "up to about 90%".
As we've indicated in several reports, the productive consumption and use of Coal liquefaction residues can contribute greatly to both the economic and the environmental viability of a Coal liquefaction process. And, one such use for the still-carbonaceous, but mostly inorganic mineral solid residues arising from a direct Coal liquefaction process, similar at least in concept to the West Virginia Process, has been established by one corporation whose name everyone should recognize, as seen in our report of:
West Virginia Coal Association | Exxon Converts Coal Conversion Residues to Cement | Research & Development; concerning: "United States Patent 4,260,421 - Cement Production from Coal Conversion Residues; 1981; Assignee: Exxon Research and Engineering Company;
Abstract: Cement is produced by feeding residue solids containing carbonaceous material and ash constituents obtained from converting a carbonaceous feed material into liquids and/or gases into a cement-making zone and burning the carbon in the residue solids to supply at least a portion of the energy required to convert the solids into cement".
Herein, we learn that West Virginia University, in concert with one of their corporate partners, has established a similar technology for utilizing such mostly-mineral residues, as likely would be co-produced by the West Virginia Process for direct Coal liquefaction.
But, some explanation and discussion seem in order.
Our interpretation of the US Patent Application we present to you in this dispatch is, that, in a way similar to two additional, and closely related, Applications we will make report of in the very near future, this isn't really so much about the utilization of Coal liquefaction residues, despite it's title, as it is about more fully formalizing and defining the efficient process of Coal liquefaction that has been established by West Virginia University and, again, at least one of their corporate partners.
Only coincidentally does it explain that the mineral residues left behind by a process of Coal liquefaction have value as a raw material for the making of Portland-type Cement.
We'll attempt to explain that more fully as we go along, with comments and additional reference links inserted in our excerpts from the initial link in this dispatch to:
"United States Patent Application 20120090510 - Forming Cement as a By-Product of Coal Liquefaction
Date: April 19, 2012
Inventor: Alfred H. Stiller, Morgantown, WV
(Chemical Engineering - Dr.Alfred H. Stiller; "West Virginia University; College of Engineering and Mineral Resources; Department of Chemical Engineering; Dr. (Alfred H.) Stiller has worked in the energy area since 1976. His work has concentrated on the areas of (1) coal dissolution, (2) reclamation of despoiled mine lands, and (3) iron sulfide compounds for coal liquefaction catalysis. His efforts in coal dissolution include the use of novel solvents in a coal extraction process. These studies have led to a patented process. He is currently studying the production of precursors for carbon materials from coal. Dr. Stiller's highest activity is coal conversion with the goal of producing the entire range of carbon materials from coal. One of the focal points of this activity is the production of graphitizable carbon foam structures which might have a myriad of applications in modern technology.")
Assignee: Quantex Research Corporation, Calgary, Canada
(West Virginia Coal Association | WVU CO2-Free Coal to Oil | Research & Development; "October 11, 2010; West Virginia University researchers have developed a way to convert coal into synthetic oil in a carbon dioxide-free economical process and, through a licensing agreement, two international firms are planning to demonstrate its viability. Quantex Energy Inc. of Canada and New Hope Corporation Ltd of Australia announced an agreement in September to commercialize the technology acquired under license from WVU. The companies are hoping to eventually produce up to 50,000 barrels of synthetic oil per day in up to three different demonstration facilities. The plan calls for New Hope and Quantex to have a 25-year exclusive license for the WVU technology that converts coal into synthetic crude oil. This new process is cheaper than previous systems and does not produce any carbon dioxide."
We presume from the above and from the formal assignment of rights to this US Patent Application, that the licensing agreement is genuinely exclusive and extends to ownership of related inventions. Herein lies another opportunity for a Coal Country journalist to get off his or her dead can and define the true extent and nature of the relationship. It is more fully reported in:
Quantex Energy Inc. Announces Strategic Investment by New Hope Corporation Limited of Australia in Breakthrough Coal to Liquid; "Quantex Energy Inc. Announces Strategic Investment by New Hope Corporation of Australia in Breakthrough Coal to Liquids Technology; 2010; Quantex Energy Inc. (QEI), a private Alberta-based company, is pleased to announce that New Hope Corporation Limited (NHC), a public company operating three open-cut thermal coal mines in Australia, has made a strategic equity investment in the company through its energy initiative, New Hope Energy Pty Ltd. (NHE). QEI has a 25-year exclusive license to a patented (pending) technology, developed by West Virginia University, which creates high value carbon products using a direct coal liquefaction process. The Quantex Process has superior environmental performance over many of the competitor technologies, produces a synthetic crude oil (SCO) and high grade synthetic coke with high carbon conversion rates from a range of coal types".
And, as seen in:
Westcore Announces Letter Of Intent With Quantex For Coal-To-Liquids Process | New Technology Magazine; "Westcore Announces Letter of Intent with Quantex for Coal-To-Liquids Process; 2011; Westcore Energy Ltd. has announced it has entered into a letter of intent with Quantex Research Corporation in respect of a proposed licence to Westcore of the Quantex coal-to-liquids process. The licence will provide for the right to use the Quantex coal-to-liquids process within the provinces of Saskatchewan and Manitoba. Upon effect, the license will entitle Westcore to build and operate one or more commercial plants using the Quantex coal-to-liquids process, to a maximum aggregate production volume of 100,000 barrels per day of the petroleum and carbon-based or related products produced using this process. As consideration for the license, Westcore will pay a license fee and a royalty to Quantex. As noted in Westcore's prior news releases,
Westcore has delivered a 500 kilogram sample of coal to the Quantex laboratory in Morgantown, West Virginia";
that relationship between Quantex and WVU appears to have grown very close. - JtM)
Abstract: The present disclosure provides methods and systems for coal liquefaction and obtaining a cement by-product. A method of obtaining a cement by-product of coal liquefaction may include exposing a coal to a hydrogenated vegetable oil in the presence of a coal-derived solvent to form a slurry, elevating the temperature of the slurry to facilitate liquefying the coal and liberating a volatile matter, separating the insoluble components from the slurry, heating the insoluble components to liberate a volatile matter and an entrained solvent, blending the insoluble components with a calcareous material and roasting the blend in a kiln at a temperature greater than 1000 degrees Celsius to obtain a clinker, and grinding the clinker to obtain a cement.
Claims: A method of obtaining a cement by-product of coal liquefaction, comprising: exposing a coal to a hydrogenated vegetable oil in the presence of a coal-derived solvent to form a slurry; elevating the temperature of the slurry to facilitate liquefying the coal and liberating a volatile matter; separating the insoluble components from the slurry; heating the insoluble components to liberate a volatile matter and an entrained solvent; blending the insoluble components with a calcareous material and roasting the blend in a kiln at a temperature greater than 1000 degrees Celsius to obtain a clinker; and grinding the clinker to obtain a cement.
Background and Field: The present invention relates to coal-to-liquid technology, and specifically to a system and method for liquefying coal using solvents that hydrogenate under mild conditions.
Coal-to-liquid technology refers to chemical processes that convert solid coal into liquid fuels and chemicals. The hydrogen to carbon ratio (H/C, molar) of coal is about 0.8 while that of liquid fuels is about 2.0. The main functions of the coal-to-liquid processes are breakage of the coal's molecular size and addition of hydrogen into coal, or in other words, destructive hydrogenation of coal. These processes are generally termed as coal liquefaction.
Coal liquefaction may occur by two different pathways: indirect liquefaction and direct liquefaction. The indirect method converts coal to hydrogen and carbon monoxide, and syngas by reacting coal with steam at high temperatures in an oxygen-starved combustion process. Direct liquefaction includes reaction of coal with hydrogen in a manner that coal becomes liquid. However, direct coal liquefaction has been historically carried out with hydrogen gas, which requires high temperature and pressure. In an example, direct coal liquefaction may involve temperatures in excess of 450 C and 2000 psi pressure.
Tetralin has been used as a donor solvent. However, a large overpressure of hydrogen and high temperature is needed to transfer the hydrogen from the gas phase to naphthalene, which is produced when tetralin is dehydrogenated as it transfers hydrogen to coal molecules. Thus, in situ re-hydrogenation during liquefaction can be rather costly.
In view of the limitations discussed above, there exists a need for a method of coal liquefaction utilizing an inexpensively produced, effective hydrogen donor solvent to digest coal.
Summary: In an aspect, the present invention provides methods and systems for inexpensively producing an effective solvent to digest coal. Alternatively, the methods and systems may enhance the dissolution ability of heavy aromatic oils by the addition of a hydrogenated liquid. In an embodiment, the hydrogenated liquid may be partially or fully hydrogenated vegetable oil.
Coal-to-liquid technology refers to chemical processes that convert solid coal into liquid fuels and chemicals. The hydrogen to carbon ratio (H/C, molar) of coal is about 0.8 while that of liquid fuels is about 2.0. The main functions of the coal-to-liquid processes are breakage of the coal's molecular size and addition of hydrogen into coal, or in other words, destructive hydrogenation of coal. These processes are generally termed as coal liquefaction.
Coal liquefaction may occur by two different pathways: indirect liquefaction and direct liquefaction. The indirect method converts coal to hydrogen and carbon monoxide, and syngas by reacting coal with steam at high temperatures in an oxygen-starved combustion process. Direct liquefaction includes reaction of coal with hydrogen in a manner that coal becomes liquid. However, direct coal liquefaction has been historically carried out with hydrogen gas, which requires high temperature and pressure. In an example, direct coal liquefaction may involve temperatures in excess of 450 C and 2000 psi pressure.
Tetralin has been used as a donor solvent. However, a large overpressure of hydrogen and high temperature is needed to transfer the hydrogen from the gas phase to naphthalene, which is produced when tetralin is dehydrogenated as it transfers hydrogen to coal molecules. Thus, in situ re-hydrogenation during liquefaction can be rather costly.
In view of the limitations discussed above, there exists a need for a method of coal liquefaction utilizing an inexpensively produced, effective hydrogen donor solvent to digest coal.
Summary: In an aspect, the present invention provides methods and systems for inexpensively producing an effective solvent to digest coal. Alternatively, the methods and systems may enhance the dissolution ability of heavy aromatic oils by the addition of a hydrogenated liquid. In an embodiment, the hydrogenated liquid may be partially or fully hydrogenated vegetable oil.
(Note, in the immediately above, the potentials for both improving sustainability and for Carbon recycling. We further note that by far the bulk of the Disclosure is given over to fuller exposition of the Coal liquefaction process. The utilization of the residues in the making of Cement is barely mentioned; and, it's only by way of saying, that, almost of course, silica-containing minerals can be tossed into a Cement kiln with limestone, or another source of, ultimately, Calcium Oxide, which could include, we submit, such things as egg and clam shells, and be transformed in the kiln into Cement clinker.)
The present invention may also provide a process that may liquefy coal without the need to hydrogenate the solvent. In embodiments, this may occur by the use of an additive that may contain hydrogen, which may result in de-polymerizing large coal molecules, while also suppressing recombination; thus, resulting in smaller overall molecular distribution and creating a liquid.
The present invention may also provide a process that may liquefy coal without the need to hydrogenate the solvent. In embodiments, this may occur by the use of an additive that may contain hydrogen, which may result in de-polymerizing large coal molecules, while also suppressing recombination; thus, resulting in smaller overall molecular distribution and creating a liquid.
(The "hydrogenated vegetable oil" is, as immediately above, "an additive that may contain hydrogen".)
In an aspect, a method of obtaining a de-ashed coal extract includes exposing a coal to a hydrogenated vegetable oil in the presence of a coal-derived solvent to form a slurry, elevating the temperature of the slurry to facilitate liquefying the coal and liberating a volatile matter, and separating the insoluble components from the slurry to obtain a de-ashed coal extract, wherein the coal extract is suitable for downstream processing.
The method may further include heating the insoluble components to liberate a volatile matter and an entrained solvent, blending the insoluble components with a calcareous material and roasting the blend in a kiln at a temperature greater than 1000 degrees Celsius to obtain a clinker, and grinding the clinker to obtain a cement.
The de-ashed coal extract may be added to a pipeline of petroleum crude for delivery to a petroleum refinery."
-------------------------
The "downstream processing" for "the coal extract" they mention above, is, rather obviously, what would take place in "a petroleum refinery".
And, "the insoluble components" separated from "the slurry" can simply be tossed into the feed stream of a Cement "kiln", after blending with a "calcareous material" to boost, if needed, the Calcium content of what is, essentially, Coal Ash, in a way that might be typified by the process disclosed in our report of:
West Virginia Coal Association | Pittsburgh Converts Coal Ash and Flue Gas into Cement | Research & Development; concerning: "United States Patent 5,766,339 - Producing Cement from a Flue Gas Desulfurization Waste; 1998; Assignee: Dravo Lime Company, Pittsburgh; Abstract: Cement is produced by forming a moist mixture of a flue gas desulfurization process waste product containing 80-95 percent by weight calcium sulfite hemihydrate and 5-20 percent by weight calcium sulfate hemihydrate, aluminum, iron, silica and carbon (and) wherein said source of aluminum and iron comprises fly ash".
As we will again emphasize in coming reports about the Coal liquefaction technology invented, as seemingly stipulated herein, by West Virginia University scientists working in "the Quantex laboratory in Morgantown, West Virginia", there are, through the use of such things as hydrogenated vegetable oil" in a Coal conversion process that "does not produce any carbon dioxide", strong elements of economy and sustainability.
Those in addition to the environmental and economic benefits accruing from, as in the Disclosure of our subject herein, "United States
Patent Application 20120090510 - Forming Cement as a By-Product of Coal Liquefaction", the extra income and disposal cost avoidance realized through the use of "Coal Liquefaction" mineral residues in the making of "Cement".
And, as we will see, things are now moving rather quickly, especially in regards to the Disclosure's affirmation that the "de-ashed coal extract may be added to a pipeline of petroleum crude for delivery to a petroleum refinery".
That, by the way, is actually a tip for any Coal Country journalists who might be finally getting motivated enough to, we submit with only the faintest of apologies for repeating the refrain, get off their dead cans and at least make a few phone calls.