Exxon Research and Engineering Company

Lavanga R Veluswamy

Peter S Maa

Lonnie W Vernon

Frank Hershkowitz

Harry William Deckman

Russell J Koveal

James H Taylor, Jr

Robert P Reynolds

Leonard Schoenman

James N Francis

Constantine P Gonatas

Charles A Euker, Jr

Jack I Ito

John W Fulton

Charles J Vadovic

Charles A Mims

Alfredo M Lopez

A novel fluidized bed syngas (FBSG) injector/reactor apparatus and an efficient process for the partial oxidation and steam reforming of light hydrocarbon gases such as methane, to convert such gases to useful synthesis gas containing CO and H.sub.2 for recovery and/or subsequent hydrocarbon synthesis. Sources of a light hydrocarbon gas, such as methane, and oxygen or an oxygen-containing gas are preheated and pressurized and injected through gas orifices of an injector at high velocity and comparable momentums into admixture with each other in the desired proportions, at a plurality of mixing chambers or recessed cups which are open to the fluidized bed reaction zone of a reaction chamber and are spaced over the face of the injector, to form a reactant gas premix having a pressure drop of at least 1% through the injector. The gaseous premix is injected in a time period which is less than its autoignition time, preferably less than 9 milliseconds, at a velocity between about 25 to 1000 feet/second, into a partial oxidation reaction zone comprising a fluid bed catalyst so that the gas mixture reacts in the catalyst bed, to reduce the amounts of CO.sub.2, H.sub.2 O and heat produced by the partial oxidation reaction to favor the desired stoichiometry. The formed syngas is cooled and recovered, such as use in further synthesis processing.

Face-mixing fluid bed process and apparatus for producing synthesis gas

This invention relates to a catalytic process for converting a carbonaceous material to a liquid product. More specifically, this invention relates to a process for hydroconverting coal in a hydroconverting zone to liquid hydrocarbon products in the presence of a catalyst prepared in situ, with the catalyst being added to a mixture of coal and solvent as an oil soluble metal compound. An increased quantity of liquid product is achieved by incorporating a hydrocracking zone into the process.

Catalytic hydroconversion process

This invention relates to a process for converting a carbonaceous material to a liquid product using a hydrogen donor solvent. More specifically, this invention relates to a process for hydroconverting carbonaceous material in which a 400.degree.-1000.degree. F. hydroconversion product fraction is further hydrocracked and a hydrocracked fraction is used as the hydrogen donor solvent. An increased quantity of liquid product is achieved by removing an ash residuum from the hydroconversion product fraction prior to the hydrocracking process.

Hydroconversion process for a carbonaceous material

An improved liquefaction process for solid carbonaceous materials wherein at least a portion of the liquefaction is accomplished in the presence of an added hydrogenation catalyst and a solvent containing at least 1.25 wt % donatable hydrogen and in the presence of partially liquefied, solid carbonaceous material at liquefaction conditions. In a preferred embodiment, the liquefaction is accomplished in a plurality of stages and a solvent containing at least 1.25 wt % donatable hydrogen is used in at least one stage, most preferably in the second stage. The partially liquefied solid carbonaceous material may be taken from the bottoms fraction of the effluent from any of the liquefaction stages.

Liquefaction process

Metal constituents are recovered from the heavy bottoms produced during the liquefaction of coal and similar carbonaceous solids in the presence of a catalyst containing a metal capable of forming an acidic oxide by burning the heavy bottoms in a combustion zone at a temperature below the fusion temperature of the ash to convert insoluble metal-containing catalyst residues in the bottoms into soluble metal-containing oxides; contacting the oxidized solids formed in the combustion zone with an aqueous solution of a basic alkali metal salt to extract the soluble metal-containing oxides in the form of soluble alkali metal salts of the metal-containing oxides and recycling the soluble alkali metal salts to the liquefaction zone. In a preferred embodiment of the invention, the bottoms are subjected to partial oxidation, pyrolysis, coking, gasification, extraction or a similar treatment process to recover hydrocarbon liquids and/or gases prior to the burning or combustion step.

Recovery of coal liquefaction catalysts

Coal or a similar solid carbonaceous feed material is converted into lower molecular weight liquid hydrocarbons by contacting the feed material with a hydrogen-donor solvent containing above about 0.6 weight percent donatable hydrogen and molecular hydrogen in a liquefaction zone or a series of two or more liquefaction zones under liquefaction conditions in the presence of an added carbon-alkali metal catalyst comprising a carbon-alkali metal reaction product prepared by heating an intimate mixture of carbonaceous solids and an alkali metal constituent to a temperature above about 800.degree. F. in a reaction zone external to the liquefaction zone.

Catalytic hydrogen-donor liquefaction process

Coal or similar liquefiable carbonaceous solids are converted into hydrocarbon liquids by contacting the feed solids with molecular hydrogen in the absence of an added hydrocarbon solvent and in the presence of an added alkali metal compound under liquefaction conditions in one or more liquefaction zones.

Coal conversion in the presence of added alkali metal compounds

Coal or similar liquefiable carbonaceous solids are converted into lower molecular weight liquids by contacting the feed solids with molecular hydrogen in the absence of externally added hydrocarbon liquids and in the presence of added hydrogen sulfide under liquefaction conditions in one or more liquefaction zones.

Coal conversion in the presence of added hydrogen sulfide

Coal or similar liquefiable carbonaceous solids are converted into lower molecular weight liquids by contacting the feed solids with molecular hydrogen in the absence of externally added hydrocarbon liquids under liquefaction conditions during sequential residence in two or more liquefaction zones arranged in series and operated such that the temperature in each zone increases from the first to the final zone. The effluent from each liquefaction zone is passed to the next succeeding higher temperature zone in the series. No hydrocarbon liquids are added to the first zone in the series and the only liquids present in each succeeding zone of the series are the liquids in the effluent from the preceding zone. Liquid hydrocarbonaceous products are recovered from the effluent withdrawn from the last zone.

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Houston, TX, United States of America

Lavanga R Veluswamy