First, we remind you, that, as seen in our report of:
West Virginia Coal Association | WVU Says Oil From Coal Could Sustain Us For 1,000 Years | Research & Development; concerning a report made by West Virginia University to the United States Department of Energy: "'Development of Continuous Solvent Extraction Processes For Coal Derived Carbon Products'; December 31, 2009; Authors: Elliot Kennel, et. al.; Research Organization: West Virginia University; Sponsoring Organization: US Department of Energy; Contract Number: FC26-03NT41873"; and, which WVU report said, in part: "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";
West Virginia University determined, for the USDOE, that, based on known technology for converting Coal into synthetic crude oil, we could "eliminate" all of our current need for imported petroleum.
Further, West Virginia University went on to say that we have enough Coal in the ground, in the USA, to be self-sufficient in our supply of such synthetic petroleum for more than 1,000 years.
Even further, as we reported most recently in:
West Virginia Coal Association | WVU Coal and Carbon-recycling Renewables into Crude Oil | Research & Development; concerning, primarily:"United States Patent 8,597,382 - Rubber Material In Coal Liquefaction; 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 ... wherein the rubber material is from a rubber tire (and wherein the product) coal extract may be added to a pipeline of petroleum crude for delivery to a petroleum refinery"; and which also contained links to our prior reports 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. ... The de-ashed coal extract may be added to a pipeline of petroleum crude for delivery to a petroleum refinery"; and: "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";West Virginia University has also demonstrated that we can incorporate renewable, carbon-recycling wastes and agricultural products in such Coal-to-Petroleum processes, thereby extending the basic Coal resource, and introducing a significant note of sustainability into such an industry.
And, herein, we see learn the accomplished WVU scientists, Alfred H. Stiller and Elliot B. Kennel, named as co-inventors of "United States Patent 8,465,561 - Hydrogenated Vegetable Oil in Coal Liquefaction", again teamed up to develop what might be seen as a comprehensive Coal conversion process, a "system", which was issued an official United States Patent, confirming the validity of their disclosed technology, on the very same day as :"United States Patent 8,597,382 - Rubber Material In Coal Liquefaction".
Comment follows excerpts from the initial link in this dispatch to:
"United States Patent 8,597,503 - Coal Liquefaction System
Patent US8597503 - Coal liquefaction system - Google Patents
Coal liquefaction system - West Virginia University
Date: December 3, 2013
Inventors: Alfred H. Stiller and Elliot B. Kennel, Morgantown, WV
Assignee: West Virginia University
Abstract: The present disclosure relates to a coal liquefaction system for utilizing a hydrogenated vegetable oil to liquefy coal. The system includes 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. The system may also include a distillation column that distills the de-ashed coal extract to obtain a pitch. The system may also include a coker that cokes at least one of the de-ashed coal extract and the pitch to obtain a coke.
(We will likely treat the technologies for obtaining "pitch" and "coke" in future dispatches.
Although we're certain "other downstream processing", as will be seen, is of more current interest to our readers, the pitch and coke products are as well high value products from the refining of crude petroleum, useful in, among other things, the refining of Aluminum and Iron. We won't include excerpts, but more about them can be learned via:
http://www.petcokeconsulting.
http://www.kbr.com/Newsroom/
Interestingly, not all pitch and coke byproducts of "petroleum" refining can be used. We won't include links to the issue, but, coke arising from the refining of Canadian tar sands is so loaded with sulfur and various, some toxic, metals that it can't be used for much of anything. Large piles of coke from Canadian tar sand refining are, according to news reports, building up around Detroit and Chicago. Proposals have been floated to ship it to Mexico and India, where environmental regulations are more lax, where it would be mixed with Coal and burned in electric power plants. It is too contaminated for that to be an option in the United States. Conversely, the pitch and coke which could be produced from the dissolution of Coal, as per the process of our subject, "United States Patent 8,597,503 - Coal Liquefaction System', could be made to be very high purity products, and quite useable, for instance, in anodes for metallurgical processes.
And, as seen for one example in:
West Virginia Coal Association | Consol Hydrogasifies CoalTL Residues | Research & Development; concerning: "United States Patent 4,248,605 - Gasification of Coal Liquefaction Residues"; 1981; Inventor: Michael Lancet, Pittsburgh; Assignee: Conoco, Inc., CT; Abstract: A method for gasifying the bottoms fraction from a coal liquefaction process by mixing the bottoms fraction with at least one finely-divided calcium compound selected from the group consisting of calcium oxide, calcium carbonate and calcium hydroxide ... in an amount sufficient to produce agglomerate particles upon mixing with the bottoms fraction and thereafter gasifying the resulting agglomerate particles by reacting the agglomerate particles with steam in a fluidized bed. Claims: A method for gasifying the bottoms fraction from a coal liquefaction process wherein coal is liquified by extraction of said coal by a distillable solvent ... said method consisting essentially of ... mixing said bottoms fraction with at least one finely-divided calcium compound ...; and gasifying ... said agglomerates by reacting said agglomerates with steam in a fluidized bed to produce a hydrogen-rich fuel gas";
carbonaceous residues arising from Coal conversion processes can also be treated in other ways to extract even more fuel value from them.)
Claims: A coal liquefaction system, comprising: 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; 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; a distillation column that distills the de-ashed coal extract to obtain a pitch; and a coker that cokes at least one of the de-ashed coal extract and the pitch to obtain a coke, wherein the coker comprises a coated coking drum that receives the de-ashed coal extract or the pitch, wherein the coking drum is coated with a coating comprising chromium, aluminum, nickel, or an alloy thereof.
(Again, we'll have more on such coke production processes in reports to follow. It is well-developed and understood technology.)
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.
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 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 have a vapor pressure of less than 1500 psi at temperatures less than 400 C. Separating may include at least one of centrifugation, filtration, decanting, and float separation. 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 C to obtain a clinker, and grinding the clinker to obtain a cement.
(With regards to the immediately above, see 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 method may further include distilling the coal extract under vacuum to obtain a mesophase pitch with a softening point in the range of 25 C to 160 C, wherein the mesophase pitch can be coked to obtain an anisotropic coke. The method may further include 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.
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 C to obtain a clinker, and grinding the clinker to obtain a cement.
In yet another aspect, an apparatus for coking may include a coated coking drum that receives a pitch material, wherein the coking drum is coated with a coating comprising at least one of a chromium, an aluminum, a nickel, or an alloy thereof, a heater that heats the pitch material to a coking temperature, a flash vessel that condenses liberated volatile matter, and a coated plunger, wherein the plunger is coated with a coating comprising at least one of a chromium, an aluminum, a nickel, or an alloy thereof wherein a coke formed in the apparatus is removed by the force of the plunger being pushed or pulled through the coking drum.
(Quite a lot of the Disclosure is given over to description of the coking processes. We're not reproducing many of the details, since we will likely be addressing them in future reports.)
In an aspect, a coal liquefaction system includes 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, 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, a distillation column that distills the de-ashed coal extract to obtain a pitch, and a coker that cokes at least one of the de-ashed coal extract and the pitch to obtain a coke, wherein the coker comprises a coated coking drum that receives the de-ashed coal extract or the pitch, wherein the coking drum is coated with a coating comprising at least one of a chromium, an aluminum, a nickel, or an alloy thereof.
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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Again, we haven't reproduced many of the details, as they seem to us to relate to variations on the basic principle; and, taken all together comprise the "Coal Liquefaction System" which, in it's entirety, would enable us to - - using our abundant domestic Coal, in combination with home-grown agricultural produce and some too-abundant domestic wastes - - completely replace any and all of the products we now indenture our grandchildren's futures, and wage foreign wars to maintain our right to do so, by buying from the alien nations of OPEC.
It's difficult for us, here, to imagine that such developments involving such a strategic use for Coal, with their implications for much greater national security and vastly enhanced national prosperity, originating as they have at a keystone of the US Coal Country higher education system, would remain of little interest to the Coal Country press and the Coal Country public.
Such, though, does sadly seem to be the case.
Our only suggestion would be to, the next time you fill up your tank with OPEC fuel at the local convenience store pumps, don't be tempted to spend your change in the newspaper vending machine by the door.
Use it instead to buy a postage stamp - - so that you can write your congressman or congresswoman and ask them to check out the Research and Development section on the West Virginia Coal Association's web site. Don't forget to ask them to get back to you with their thoughts, so that you'll have something to think about come the next November of an even-numbered year.