Production of liquid and gaseous fuel products from coal or the like

Abstract

A continuous deep hydrogenation coal liquefaction process is disclosed wherein a slurry of powdered coal or other carbonaceous material in a recycle solvent is passed with hydrogen through a hydroextraction unit, the heavy coal extract remaining after removal of gas and oil is then fed into a low-temperature fluidized-bed pyrolysis unit, and the char and ash is fed from the pyrolysis unit to a high-temperature fluidized-bed char gasification unit. The gasification unit is specially constructed to provide continuous ash agglomeration and has a funnel-shaped grid plate at the bottom of the fluidized bed and an elutriation leg of reduced diameter at the bottom of the grid plate. Air or oxygen is introduced near the top of the elutriation leg to provide a high temperature such that the ash particles are continuously softened and caused to accrete or agglomerate in a hot spouting zone at the base of the grid plate. Steam is directed upwardly through the elutriation leg so that the smaller lighter agglomerated ash particles are supported in the bed and the larger heavier agglomerated ash particles fall to the bottom for removal. A portion of the hot agglomerated ash from the upper portion of the bed is continually recycled through the pyrolysis unit to function both as a catalyst and as the sole heat source. A portion of the ash may also be recycled with the slurry fed to the hydroextraction unit to serve as a hydrogenation catalyst.