West Virginia University has established a complete and thorough technology for the efficient and practical conversion of our abundant Coal into substitute liquid crude petroleum.
Moreover, as seen in our reports of:
West Virginia Coal Association | WVU June 18, 2013, Carbon-Recycling Coal Liquefaction | Research & Development; concerning: "United States Patent 8,465,561 - Hydrogenated Vegetable Oil in Coal Liquefaction; June 18, 2013; Inventors: Alfred H. Stiller and Elliot B. Kennel, Morgantown, WV; Assignee: West Virginia University; Abstract: The present disclosure provides methods and systems for coal liquefaction using a hydrogenated vegetable oil. 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"; and:
West Virginia Coal Association | WVU May 28, 2013, Carbon-recycling Coal Liquefaction | Research & Development; concerning: "United States Patent 8,449,632 - Sewage Material in Coal Liquefaction; May 28, 2013; Inventor: Alfred H. Stiller, Morgantown, WV; Assignee: West Virginia University; Abstract: The present disclosure provides methods and systems for coal liquefaction using a sewage material. A method of obtaining a de-ashed coal extract includes exposing a coal to a sewage material 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 (and wherein) the coal ...is selected from one or more of a sub-bituminous coal, a bituminous coal, a lignite coal and an anthracite coal (and) wherein the sewage material is ... sewage sludge. (Further) the methods and systems may enhance the dissolution ability of heavy aromatic oils by the addition of a hydrogenated liquid (and) the hydrogenated liquid may be partially or fully hydrogenated vegetable oil. 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";West Virginia University has enabled, in their Coal-to-Petroleum processes, the inclusion and productive consumption of Carbon-recycling botanical produce and certain noxious wastes, with resultant implications for the expansion of agricultural industry, the resolution of some human waste disposal issues, and, the potential for ongoing sustainability even in the face of, eventually, declining Coal reserves.
Even further, as we reported last October, in:
West Virginia Coal Association | WVU & Canada Cement from Coal Liquefaction Residues | Research & Development; concerning: "United States Patent Application 20120090510 - Forming Cement as a By-Product of Coal Liquefaction; April 19, 2012; Inventor: Alfred H. Stiller, Morgantown, WV; Assignee: Quantex Research Corporation, Calgary, Canada; 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";
West Virginia University scientists, the venerable Alfred H. Stiller primary among them, have established a technology whereby the mineral residua left by the conversion of Coal's carbon content into liquid hydrocarbon crude petroleum can be completely consumed and utilized in the making of a substitute for the essential commodity, Portland-type Cement; thereby conserving both energy and other natural mineral resources.
We remind you, that, as seen previously in our reports of:
West Virginia Coal Association | Standard Oil Converts Coal Conversion Residues into Cement | Research & Development; concerning: "United States Patent 4,174,974 - Process for Converting Coal Ash Slag into Portland Cement; 1979; Assignee: Standard Oil Company of Indiana, Chicago; Abstract: Disclosed is a manufacturing process for converting coal ash slag from a slagging coal gasifier into a marketable cement product having the characteristics and qualities of portland cement. This process also provides an efficient means to conserve energy when producing a portland cement and provides an effective and economical way to dispose of a waste product while increasing the cost efficiency of a slagging coal gasifier"; and:
West Virginia Coal Association | Illinois Converts Coal Conversion Ash into Cement | Research & Development; concerning: "United States Patent 4,396,432 - Process for Converting Coal to Gaseous Fuel with Production of Portland Cement as a By-product; 1983; Assignee: University of Illinois Foundation, Chicago; Abstract: Continuous process for converting coal to gaseous fuel with production of Portland cement as a by-product comprises the step of pelletizing a mixture of finely divided coal and limestone, heating (coking) the pellets in a reducing gas atmosphere to liberate volatile fuel products, and converting a substantial proportion of the residual carbon in the pellets to CO and hydrogen by the water-gas reaction, the inorganic constituents of the coal being simultaneously converted to Portland cement clinkers"; and:
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";
such potentials for the further, productive and profitable, conversion, into Portland-type Cement, of the mineral residua left behind by the extraction, by whatever method, of Coal's carbon content for conversion into various hydrocarbons, has already been well-established by others.
And, herein, we learn that technical experts in the employ of our United States Government just recently confirmed that West Virginia University has, indeed, further developed that concept and technology by applying it to their own novel technologies for converting Coal into synthetic crude petroleum.
As seen, with comment inserted and appended, in excerpts from the initial link in this dispatch to:
"United States Patent 8,512,551 - Forming Cement as a By-Product of Coal Liquefaction
Patent US8512551 - Forming cement as a by-product of coal liquefaction - Google Patents
Forming cement as a by-product of coal liquefaction - West Virginia University
Date: August 20, 2013
Inventor: Alfred H. Stiller, Morgantown, WV
Assignee: West Virginia University
(Note: Herein is another opportunity for Coal Country journalists. In our original report of "United States Patent Application 20120090510 - Forming Cement as a By-Product of Coal Liquefaction", from which we here are convinced our subject herein, "United States Patent 8,512,551", has evolved, WVU's Canadian partner, "Quantex Research Corporation", was the prospective Assignee of rights. In that original report, we included some information concerning Quantex, and their Australian partners, and the plans that were evolving to establish some Coal liquefaction demonstration projects. What has changed? And, what are the plans now?)
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.
(The specified temperature is not extreme. As can be learned from the Portland Cement Association, via:
Concrete Technology | Cement standards and specifications | Portland Cement Association (PCA); "Cement’s Role in Sustainability"; temperatures in cement kilns typically reach 1450 C. And, don't be distracted by the perhaps unfamiliar "Celsius". Though there are niggling differences, it is essentially equivalent to "Centigrade" - - difficult as that itself is for us old Fahrenheit cave dwellers to assimilate.)
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.
(As seen for just one example in our report of:
West Virginia Coal Association | California Hydrogasifies Coal & Carbon-Recycling Wastes | Research & Development; concerning: "United States Patent 7,500,997 - Steam Pyrolysis ... to Enhance the Hydro-Gasification of Carbonaceous Materials; 2009; Assignee: The Regents of the University of California; Abstract: A process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid fuel in a substantially self-sustaining process. (A) slurry of carbonaceous material in water, and hydrogen from an internal source, are fed into a hydro-gasification reactor to generate methane rich producer gases which are fed into a steam pyrolytic reformer to generate synthesis gas comprising hydrogen and carbon monoxide. A portion of the hydrogen is used as the internal hydrogen source. The remaining synthesis gas is either used as fuel to produce electricity and/or process heat or is fed into a Fischer-Tropsch reactor to produce liquid fuel. (And) wherein the carbonaceous material comprises municipal waste, biomass, wood, coal, or a ... synthetic polymer";such "indirect liquefaction" technologies are as well becoming more sophisticated, and are being designed to, like West Virginia University's processes of "United States Patent 8,449,632 - Sewage Material in Coal Liquefaction" and "United States Patent 8,465,561 - Hydrogenated Vegetable Oil in Coal Liquefaction", incorporate renewable, Carbon-recycling materials and wastes into the Coal conversion 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 psig 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.
(The above "Tetralin" is an hydrogenated version of the primary Coal oil, or tar, "naphthalene"; and, it has been known to have Coal dissolution and hydrogenation capabilities for many decades. For a more recent dissertation touching on it, see our report of:
West Virginia Coal Association | WVU Hydrogenates Coal Tar | Research & Development; concerning: "'Hydrogenation of Naphthalene and Coal Tar Distillate over Ni/Mo/Al2O3 Catalyst'; Abhijit Bhagavatula; West Virginia University; 2009; Abstract: The hydrogenation of naphthalene and coal-tar distillates has been carried out in a Trickle Bed Reactor, in which the liquid is allowed to flow through the catalyst bed in the presence of hydrogen. ... A model compound naphthalene dissolved in a solvent, n-hexadecane, was used to replicate the hydrogenation of coal tar distillates. The operating conditions employed for the hydrogenation of naphthalene (were varied, and the results monitored, and a) unique peak for naphthalene was observed ... (as was) the peak for the hydrogenated product, tetralin".)
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. 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.
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.
In an aspect, a method of obtaining a de-ashed coal extract may include exposing a coal to a petroleum crude 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.
In an aspect, a method of obtaining a de-ashed coal extract may include exposing a coal to a rubber material 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 rubber material may be from a rubber tire.
In an aspect, 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.
In another aspect of the invention, the methods and systems may produce a slurry of coal liquids and undissolved coal particles. The slurry may be further refined to produce a pitch, which may be considered a final product or alternatively may be upgraded to produce lighter hydrocarbon synthetic crude for fuels and chemicals."
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We'll close our excerpts there, but with a note that there is much we have not reproduced, including excerpts from extended discussion of other valuable products, like synthetic "pitch", that, in addition to "synthetic crude for fuels and chemicals", can be made from the "slurry of coal liquids and undissolved coal particles" produced by "the invention".
But, in sum, there you have it:
Our United States Government has officially confirmed that West Virginia University knows how to directly and efficiently convert Coal, along with various, some Carbon-recycling, wastes, such as "sewage sludge" and scrapped "rubber tire"s, and, along with continuously renewable Carbon-recycling products of agriculture, like "vegetable oil", into "synthetic crude" which can "be added to a pipeline of petroleum crude for delivery to a petroleum refinery".
West Virginia University has herein an important lesson for us:
We can now start using our by far most abundant fossil energy resource, Coal, to free our nation from economic and diplomatic slavery to OPEC; to stem our hemorrhage of foreign exchange; to put more of our own US citizens to work; and, to lay the foundation of an industry arising from the noble enterprises of farming and recycling that would provide for our nation's need for hydrocarbon fuels and chemicals until our sun burns itself to a cinder.
And, according further to West Virginia University herein, we can use the relatively inert mineral wastes arising from such bountiful production of hydrocarbon fuels and chemicals to manufacture one of our most basic materials, i.e., Cement, for the durable construction of our built environment.
Those few of us here, in our isolated little outpost of exile and study, remain puzzled that such developments and innovations seemingly remain of little interest to the Coal Country press.
West Virginia University didn't fare as well as we all had hoped yesterday in this season's inaugural game in the Big Twelve.
But, herein, via disclosure of "United States Patent 8,512,551 - Forming Cement as a By-Product of Coal Liquefaction", they've tossed a beautiful, game-changing, game-winning, touchdown pass on a tight spiral.
Now, we have to wait and see if our Coal Country press corps is good enough to catch it and carry it into the end zone, maybe get the crowd into what is truly a big game for all of us. We feel like we're in the fourth quarter; and, so far, they've been playing like rookies with other things on their minds.