Kerr-Mcgee Corporation

Kerr-Mcgee Chemical, LLC

Donald E Rhodes

Roger A Baldwin

Robert E Leonard

Robert E Davis

Alfred H Knebel

Srikant Gir

A method for sequentially co-processing heavy hydrocarbon materials and carbonaceous materials comprising first subjecting the heavy hydrocarbon material in the presence of a disposable metal catalyst to produce and separate therefrom a first distillate stream and a first non-distillable effluent stream containing the disposable metal catalyst. The first non-distillable effluent stream then is mixed with the carbonaceous material and the mixture subjected to liquefaction conditions in the presence of said disposable metal catalyst. The liquefaction product then is subjected through the use of sequential fractionation and critical solvent extraction processing steps to separate and recover various heavy hydrocarbon and carbonaceous-derived light hydrocarbon liquid products therefrom.

Method for sequentially co-processing heavy hydrocarbon and carbonaceous

A multi-stage coal liquefaction method in which coal is slurried with a primary light solvent, such as toluene, hexane and/or cyclohexane, and a process-derived primary heavy solvent. The coal-primary solvent slurry is treated under coal-liquefying conditions to form a first feed solution containing coal liquefaction products. The first feed solution is treated by a multi-stage supercritical solvent extraction procedure. The final heavy phase produced by this procedure is mixed with a secondary solvent, such as pentane, to produce a second feed mixture, which is treated in a second multi-stage supercritical solvent extraction procedure. Heavy phases recovered from the separate stages of both solvent extraction procedures are blended to provide a recycled primary heavy solvent.

Multi-stage coal liquefaction and fractionation method

A method of liquefying coal in which coal is mixed with a process solvent comprising at least partially hydrogenated coal tar material to produce a coal-solvent slurry. This slurry is treated under coal-liquefying conditions, preferably including a hydrogen atmosphere and elevated temperatures, to produce a solution containing coal liquefaction products. These products are recovered from the solution. Recovered, process-derived solvent material may be recycled in order to supplement the at least partially hydrogenated coal tar material as an ingredient of the process solvent.

Coal liquefaction with coal tar solvent

A process for the prevention of the deposition of entrained soluble coal products from vaporous solvent recovered from a heavy fraction comprising insoluble coal products and some solvent and soluble coal products. The heavy fraction is produced in a coal deashing system employing solvent at elevated temperatures and pressures near the critical conditions of the solvent. The heavy fraction is reduced in pressure to form a mixture of ash concentrate and vaporous solvent together with entrained soluble coal products. This mixture then is turbulently admixed for at least 0.05 seconds to coalesce or condense the entrained soluble coal products upon the ash concentrate particles. The coalescence or condensation of at least a portion of the soluble coal products substantially prevents or minimizes deposition of the same in the solvent withdrawal conduit of subsequent vapor-solid separation apparatus. Alternatively, the mixture is introduced into a fluidized bed of ash concentrate. The entrained soluble coal products then coalesce or condense on the fluidized particles by contacting the same.

Process for the separation of entrained organic fluids from gaseous

A process for removing an agglomerate of accumulated materials including ash concentrate which collects within the first heavy phase withdrawal conduit of a coal deashing system employing solvent at elevated temperatures and pressures near the critical temperature of the solvent. A carrier fluid is introduced into the first heavy phase withdrawal conduit simultaneously with or after pressure reduction of the heavy phase under conditions such that a turbulent flow profile is developed within the withdrawal conduit which results in the removal of at least a substantial portion of any accumulated materials within the withdrawal conduit.

Process for the discharge of ash concentrate from a coal deashing system

A process for maintaining the fluid-like properties of separate phases formed within a continuous coal deashing process during periods in which the flow of feed to the apparatus is interrupted. In operation, when the flow of feed is interrupted, the flow of solvent to the separation apparatus of the coal deashing process is diverted about said apparatus in such a manner as to maintain the system operating pressure. More specifically, solvent maintained at elevated temperature and pressure is diverted about the mixing and separation apparatus and introduced into a conduit downstream of the separation zone, in advance of a pressure regulating valve, said conduit also connecting to the separation apparatus. The new flow path maintains the pressure within the separation zone through establishment of fluid communication between the elevated pressure solvent and the phases within the separation apparatus. In one embodiment, a heating fluid is circulated through heating jackets surrounded said separating apparatus to maintain the system operating temperature. Resumption of continuous operation is effected by returning the solvent to its former flow path in the apparatus when the flow of feed is restored.

Operation of a coal deashing process

Coal liquefaction products are contacted with a deashing solvent and introduced into a first separation zone. The first separation zone is maintained at an elevated temperature and pressure, determined to maximize the recovery of soluble coal products, to cause said coal liquefaction products to separate into a first light phase and a first heavy phase. Under these conditions the heavy phase while still fluid-like in character is substantially non-flowable. Flowability is returned to the fluid-like heavy phase by the introduction of an additional quantity of deashing solvent into the first separation zone at a location below the interface between the first light and heavy phases or into the heavy phase withdrawal conduit during withdrawal of the first heavy phase and prior to any substantial pressure reduction. The first heavy phase then is withdrawn from the first separation zone for additional downstream processing without plugging either the withdrawal conduit or the downstream apparatus. The first light phase comprising the soluble coal products is withdrawn and recovered in an increased yield to provide a more economical coal deashing process.

Process for improving soluble coal yield in a coal deashing process

An improved coal deashing process wherein a feed mixture comprising soluble coal products, insoluble coal products, and deashing solvent at a first temperature level is separated in a first separation zone into a first light fraction and a first heavy fraction comprising the insoluble coal products and some of the deashing solvent through admixing predetermined quantities of an additive with the feed mixture prior to separation to provide an improved yield of recoverable soluble coal products. Alternatively, the additive is admixed with the first light fraction prior to subsequent separations to provide an improved yield of recoverable soluble coal products.

Separation technique in a coal deashing process

A process for improving the yield of soluble coal products separated from a residuum feed in a coal deashing process. In operation, an additive comprising (i) at least a portion of a distillate fraction preferably recovered from the coal liquefaction products from which the residuum feed is derived, (ii) a portion of recycled heavy soluble coal products, (iii) a portion of recycled light soluble coal products, or (iv) admixtures thereof is introduced in predetermined quantities into the residuum feed prior to entry into a separation zone maintained at elevated temperature and pressure to effect an improved separation of the soluble coal products from the insoluble coal products within the residuum feed.

Use of specific coal components to improve soluble coal product yield in

A coal deashing process wherein a feed mixture comprising soluble coal products, insoluble coal products and solvent is separated in a first separation zone into a first heavy phase and a first light phase comprising soluble coal products, solvent and some insoluble coal products. The first light phase is withdrawn and introduced into a second separation zone wherein it separates into a second heavy phase comprising insoluble coal products, soluble coal products and some solvent and a second light phase comprising soluble coal products and solvent. The second heavy phase is withdrawn and at least a portion is recycled to the first separation zone to increase the yield of separable soluble coal products ultimately recovered by the process. In alternate embodiments, additional solvent can be added to the first light phase before introduction into the second separation zone or the recycled portion of the second heavy phase may be introduced into a treatment zone before reintroduction into the first separation zone. The treatment zone effects an increase in the molecular weight of at least a portion of the recycled second heavy phase which facilitates subsequent separation in the first separation zone.

Method of improving yield in a coal liquefaction product deashing process

An improved coal deashing process wherein coal is mixed with a coal liquefaction process solvent, solubilized and flashed to provide a prepared mixture and the prepared mixture is mixed with a deashing solvent to produce a feed mixture. Thereafter, the feed mixture is separated in a first separation zone into a first heavy fraction comprising insoluble coal products and a first light fraction comprising soluble coal products and solvents. The first light fraction is recovered and a second portion of the deashing solvent is mixed with the first light fraction prior to introduction into a second separation zone wherein an improved separation occurs to produce a second light fraction comprising the solvents and a second heavy fraction comprising the soluble coal products which is recovered. The second light fraction is withdrawn and separated in a third separation zone into a third heavy fraction comprising the liquefaction process solvent for recycle to aid in solubilization of the coal and a third light fraction comprising the deashing solvent for recycle to aid in the production of the feed mixture.

Coal deashing process having improved solvent recovery techniques

A process for maintaining the fluid-like properties of a heavy phase being withdrawn from a separation zone maintained at elevated temperature and pressure during periods in which the flow of this heavy phase is terminated due to pressure reduction valve plugging or to permit cleaning of downstream processing apparatus. When the flow of withdrawn heavy phase is interrupted, deashed coal is melted, if necessary, and introduced under pressure into the withdrawal conduit to mix with the heavy phase therein. The mixture of deashed coal and heavy phase retains the fluid-like properties exhibited by the heavy phase and flow can be resumed once the downstream apparatus is repaired. Alternatively, other high-boiling aromatic materials may be used instead of the deashed coal.

Growing community of inventors

Oklahoma City, OK, United States of America

Donald E Rhodes