Just in time for Christmas, 2013, our US Government granted - - and verified the truth of - - a claim made by West Virginia University:
Coal, in combination with certain sustainable and Carbon-recycling wastes and with certain renewable and Carbon-recycling agricultural produce, can be directly and efficiently converted, on a practical basis, into synthetic crude petroleum.
This is, in fact, a reconfirmation of that truth, since, as seen in our reports of:
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. Claims: A method of obtaining a de-ashed coal extract, comprising: 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 insoluble components from the slurry to obtain a de-ashed coal extract. The method ... wherein the coal-derived solvent is selected from a group comprising recycled liquefied coal, coal tar distillate, and coal tar pitch. The method ... further comprising agitating the slurry to facilitate liquefying the coal (which) is selected from one or more of a sub-bituminous coal, a bituminous coal, a lignite coal and an anthracite coal. The method ... wherein the sewage material is lignin-containing sewage sludge. 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. 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. 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 coal-derived solvent may be selected from a group comprising recycled liquefied coal, coal tar distillate, and coal tar pitch. ... The hydrogenated vegetable oil may be at least one of soybean oil, peanut oil, canola oil, olive oil, other vegetable oil or combination of at least two of these oils. The coal may be selected from one or more of a sub-bituminous coal, lignite coal and an anthracite coal. 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"; and:
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. Claims: A method of obtaining a de-ashed coal extract, 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; and separating insoluble components from the slurry to obtain a de-ashed coal extract. The method ... wherein the coal-derived solvent is selected from the group consisting of recycled liquefied coal, coal tar distillate, and coal tar pitch. The method ... wherein the hydrogenated vegetable oil is at least one of soybean oil, peanut oil, canola oil, olive oil, other vegetable oil or combination of at least two of these oils";
our United States Government technical experts already confirmed on two occasions just months ago that West Virginia University scientists, led by the estimable Professor Alfred H. Stiller, had developed processes which enabled the conversion of Coal, in concert with resource-extending and Carbon-recycling wastes and agricultural produce into a liquid product suitable "for delivery to a petroleum refinery".
And, herein we see those plain facts have been re-emphasized, and with the inclusion of even additional carbonaceous wastes and products, in excerpts from the initial link in this dispatch to:
"United States Patent 8,597,382 - Rubber Material In Coal Liquefaction
Patent US8597382 - Rubber material in coal liquefaction - Google Patents
Rubber material in coal liquefaction - West Virginia University
Date: December 3, 2013
Inventor: Alfred H. Stiller, Morgantown, WV
Assignee: West Virginia University
Abstract: The present disclosure provides methods and systems for coal liquefaction using a rubber material. A method of obtaining a de-ashed coal extract includes 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.
Claims: A method of obtaining a de-ashed coal extract, comprising: exposing a coal to a rubber material in the presence of a coal-derived solvent and a hydrogenated vegetable oil selected from partially hydrogenated vegetable oil and fully hydrogenated vegetable oil to form a slurry; elevating the temperature of the slurry to facilitate liquefying the coal and liberating a volatile matter; separating insoluble components from the slurry to obtain a de-ashed coal extract; and optionally subjecting the de-ashed coal extract to one or more downstream processes selected from (i) petroleum refining processes to form fuels, (ii) distilling to form a pitch, and (iii) distilling under vacuum to form a mesophase pitch.
The method ... wherein the rubber material is from a rubber tire.
(Concerning the beneficial effects that can be achieved by, as above, including the ubiquitous and troublesome waste stream of used auto tires in a Coal liquefaction process, see, for one example, our earlier report of:
West Virginia Coal Association | WVU Improves CTLYield with Waste Tires | Research & Development; concerning: "Effect of process conditions on co-liquefaction kinetics of waste tire and coal; Ramesh K. Sharma, Jianli Yang, John W. Zondlo and Dady B. Dadyburjor;
West Virginia University; 1998".)
The method ... wherein the coal-derived solvent is selected from a group comprising recycled liquefied coal, coal tar distillate, and coal tar pitch.
The method ... wherein separating comprises at least one of centrifugation, filtration, decanting, and float separation (and) wherein the temperature is elevated to between 300 degrees Celsius and 600 degrees Celsius (and) further comprising agitating the slurry to facilitate liquefying the coal.
The method ... wherein the coal is selected from one or more of a sub-bituminous coal, a bituminous coal, a lignite coal, and an anthracite coal.
(Additional claims disclose how the liquefied Coal can be further converted, if desired, into a "pitch", and, into what would be a rather pure "coke".)
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 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.
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.
(It might not be entirely clear, but, some of the Coal liquefaction product is, or can be, recycled, with or without hydrogenation, and used in conjunction with the vegetable oil as the Coal liquefaction solvent, as indicated in following passages concerning the "pitch", which can be further utilized in various different, optional ways.)
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. Water liberated as a result of the elevated temperature may be captured and stored.
Volatile matter may be condensed and recycled.
The method may further include distilling the coal extract to obtain a pitch. The coal-derived solvent may be selected from a group comprising recycled liquefied coal, coal tar distillate, and coal tar pitch.
The hydrogenated vegetable oil may be at least one of soybean oil, peanut oil, canola oil, olive oil, other vegetable oil or combination of at least two of these oils (and, the) method may further include agitating the slurry to facilitate liquefying the coal. The coal may be selected from one or more of a sub-bituminous coal, lignite coal and an anthracite coal. 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 C to obtain a clinker, and grinding the clinker to obtain a cement.
(Concerning the above, WVU has that option covered, as well; as seen in our report of:
West Virginia Coal Association | WVU Makes Cement from Coal-to-Petroleum Residues | Research & Development; concerning: "United States Patent 8,512,551 - Forming Cement as a By-Product of Coal Liquefaction; August 20, 2013; Inventor: Alfred H. Stiller, Morgantown, WV; Assignee: West Virginia University; 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 de-ashed coal extract may be added to a pipeline of petroleum crude for delivery to a petroleum refinery.
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 high quality coke from a low rank coal extract 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 to obtain a de-ashed coal extract that is quinoline insoluble-free, distilling the coal extract under vacuum to obtain a pitch with a suitable softening point, and coking the pitch to obtain a coke. The coke may be at least one of an anisotropic coke, a metallurgical coke, a graphite coke, an anode coke, and a needle coke. The method may further include air blowing the pitch to crosslink molecules in the pitch, the air blowing of synthetic pitch used for at least modifying a softening point and increasing coke yield.
(Note that, in addition to synthetic crude petroleum, this technology can also be employed to manufacture "high quality coke" from "low rank coal", that is, from a Coal otherwise not suitable for coking. And, the various cokes noted above, such as "metallurgical coke" and "anode coke" are indeed high-value products useful and needed in the refining of certain strategic metals, such as, in the case of "anode coke", Aluminum.)
In an aspect, a modular coal liquefaction system may include a reactor for exposing a coal to a hydrogenated vegetable oil in the presence of a coal-derived solvent to form a slurry, a heater that elevates the temperature of the slurry in the reactor to facilitate liquefying the coal and liberating a volatile matter, and a centrifuge that separates the insoluble components from the slurry to obtain a de-ashed coal extract, wherein the coal extract is suitable for downstream processing, wherein the reactor, heater, and centrifuge are adapted to be modular. The system may further include a distillation column that distills the de-ashed coal extract to obtain a pitch. The system may further include a coker that cokes at least one of the de-ashed coal extract and the pitch to obtain a coke. The system may be adapted to be modularly disposed on a rail car. The system may be adapted to be modularly disposed on a semi-truck trailer.
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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It might not be entirely clear from the foregoing, but, the option exists, as perhaps more directly stated in our final excerpted passage, to make either "pitch", and it's derivative products, as the "final product" of this Coal liquefaction process; or, to further process the "slurry" in order "to produce lighter hydrocarbon synthetic crude for fuels and chemicals".
That point is made and discussed in our recent dispatch:
West Virginia Coal Association | WVU Says Oil From Coal Could Sustain Us For 1,000 Years | Research & Development; concerning the report: "Development of Continuous Solvent Extraction Processes For Coal Derived Carbon Products; 2009; Authors: Elliott Kennel, et. al.; Research Organization: West Virginia University; Sponsoring Organization: US Department of Energy; Contract Number: FC26-03NT41873; Abstract: NETL sponsored effort seeks to develop continuous technologies for the production of carbon products, which may be thought of as the heavier products currently produced from refining of crude petroleum and coal tars obtained from metallurgical grade coke ovens. This effort took binder grade pitch, produced from liquefaction of West Virginia bituminous grade coal, all the way to commercial demonstration in a state of the art arc furnace. Other products, such as crude oil, anode grade coke and metallurgical grade coke were demonstrated successfully ... . First, direct liquefaction was accomplished with less than a percent of hydrogen per unit mass of product, or about 3 pound per barrel or less. (A) significant need exists for an environmentally clean process which can use domestically obtained raw materials and which can still be very competitive economically. ... (In the described process) coal is converted to a crude oil and a few percent gas. The synthetic crude can be further processed to output synthetic fuels of desirable quality, including a substantial gasoline fraction ... . (WVU) Demonstrated the ability to remove ash precursors via centrifugation of the extracted coal digest, thus resulting in a solution that can be further processed to make carbon products and/or the equivalent of crude petroleum. ... The coal liquefaction process described herein is suitable for expansion to multiple millions of barrels per day of crude oil that in turn can be upgraded using standard refining processes. It is therefore possible for the United States to reduce or eliminate the 12 million barrels per day of liquid crude that it currently imports. Coal liquefaction is economically attractive ... . (The) availability of coal is high (and, it) appears possible that coal could be used as a feedstock to satisfy current commercial power and liquid product needs. Assuming 300% consumption compared to today’s rates (i.e., a total of 3 billion Tonnes per year), the supply of North American coal - for value-added liquid fuels if not electric power - might plausibly last for the next 1300 years";wherein West Virginia University formally reported to the United States Department of Energy that the United States of America has enough Coal in the ground within her borders to, via a process perhaps like that disclosed by our subject herein, "United States Patent 8,597,382 - Rubber Material In Coal Liquefaction; 2013; Inventor: Alfred H. Stiller, Morgantown, WV; Assignee: West Virginia University", supply America's need for liquid hydrocarbon fuels, that is, petroleum, for at least the next millennium.
And, that estimate, apparently, concerns only the amount of Coal available to us.
It does not seem to take into account the full, resource-extending effects of including, as in "United States Patent 8,597,382 - Rubber Material In Coal Liquefaction"; and, "United States Patent 8,449,632 - Sewage Material in Coal Liquefaction"; and, "United States Patent 8,465,561 - Hydrogenated Vegetable Oil in Coal Liquefaction", various wastes and products of agriculture - - with their potentials for Carbon recycling and enhanced sustainability - - with our domestically abundant US Coal in the production of "the equivalent of crude petroleum".
West Virginia University, in an effort seemingly led by the estimable Professor Alfred H. Stiller, has shown us the way to free ourselves from ongoing economic bondage to OPEC, and, in the process, to increase our domestic employment and to improve our environment, through the establishment of an industry that would demand an increase in agricultural activity, and stimulate the productive collection and utilization of certain organic and noxious wastes. And, that industry would be founded on the increased utilization of our one far and away most abundant fossil energy resource:
Coal.