Liquefaction co-processing of coal shale oil at - Argonne National ...

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GAS GENERATION AND SEPARATION COAL SOLUBILIZATION HYDROGENATION DISTILLATION AND AGGLOMERATION SteaE (Optional) Natural Gas co Rich Bi twn Bi tmen (andlor (andlor heavy of1 1 Coal heavy oi 1 ) Recycle Mater Figure 1: Block Diagram of the ARC Two-Stage CO/Steam-K2C03 - H2 Coal/Bitumen Process Concept 207
BACKGROUND COAL LIQUEFACTION/RESID HYDROCRACKING VI A THO - STAGE INTEGRATED CO- PROCESS I NG Marvin Greene Avinash Gupta William Moon LUMMUS CREST INC. 1515 BROAD STREET BLOOMFIELD, NEW JERSEY 07003 Lummus Crest Inc. (LCI), a subsidiary of Combustion Engineering Inc., has been developing technology for the simultaneous processing of coal and heavy petroleum liquids under a joint development contract with the U. S. Department of Energy. The LCI co-processing route is an outgrowth of its Integrated Two-Stage Liquefaction (ITSL) technology developed over the past decade by LCI for coal liquefaction. A 33-month R&D contract was initiated in October 1984 with the objective of determining the technical and economic feasibility of coal liquefaction via the LCI co-processing route. The project was formulated into five major program tasks as follows: Task 1: Project Management Plan Task 2: Feedstock Analysis Task 3: Co-Processing Reactivity Screening Task 4: Continuous Bench-Scale Operations Task 5: Cost Estimate of Conceptual Commercial Facility The first three tasks have been completed and the continuous Bench-Scale Operations task has recently been initiated. The balance of this paper will describe experimental methods, the LCI co-processing approach and the results of recent bench-scale unit operations. SOME JUSTIFICATIONS FOR CO-PROCESSING Since co-processing inherently requires two separate feedstocks, namely coal and petroleum resid, it is possible to assess any potential process advantages from two viewpoints. From the refiner's viewpoint, the aromatic-rich, coal-derived extracts, being well known hydrogen donor solvents, can improve the hydroprocessing conversion of heavy, low grade petroleum feedstocks. On a constant energy cost basis, the syncrude cost contribution from a coal feedstock may be less than that from a petroleum feedstock. For example, if one assumes a typical net syncrude yield of 0.0005 M3/Kg (3.0 bbl/ton) for a run-of-mine bituminous coal priced at $0.033[5g ($30/ton), then the coal feedstock cost of the coal syncrude is about f62/M (SlO.OO/bbl). This compares to petroleum cfude prices, even under the current suppressed spot market, in excess of $74-100/M ($12-16/bbl). The situation is even more pronounced in the case of a typical subbituminous, coal. Although the net yield of liq9ds from subbitumjnous coal is lower than 'that from bituminous coal (0.0003 M /Kg vs. 0.0005 M /Kg for bituminous), the corresponding subbituminous R.O.M. coal cost is not proportionately lower but rather about 73 percent lower than that of the bituminous coal ($O.OOSS/Kg vs. $0.033/Kg). This translyes to a subbituminous Coal feedstock cost of the coal liquids of about $32.6/M ($5.20/bbl). In both cases, it is envisioned that a relatively low level of coal-derived liquids would be blended with petroleum resid feedstock so as not to greatly alter the downstream refinery processability of the petroleum-coal liquid mixtures. 208
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ABSTRACT LIQUEFACTION CO-PROCESSING
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eaction temperature, 1000-1500 psig
Page 5 and 6: 6. 7. 8. 9. 10. 11. 12. 13. 14. 15
Page 7 and 8: I 0" 100- I I I WyO-3 P 3: 1500 psi
Page 9 and 10: 11.3 A-6 yJ 600 OF, 1500 psig CO, 3
Page 11 and 12: Experimental UDqradinq and Cooroces
Page 13 and 14: catalytic to the thermal hydrogenat
Page 15 and 16: the reaction with oil production re
Page 17 and 18: TET did not promote the production
Page 19 and 20: MICROAUTOCLAVE DESCRIPTION AND PROC
Page 21 and 22: FEEDSTOCK PROPERTIES Some propertie
Page 23 and 24: CONCLUSIONS HRI's microautoclave ha
Page 25 and 26: 176
Page 27 and 28: 100. 2 8%. M = ?8. 38. .... . . . .
Page 29 and 30: CATALYTIC CO-PROCESSINS OF OHIO NO.
Page 31 and 32: CATALYST COMPARISON STUDY The premi
Page 33 and 34: fractions and a decrease of heavier
Page 35 and 36: TABLE 2 Coal Analyses I1 1 i noi s
Page 37 and 38: Temperature WHSV, G/hr/cc TABLE 6 C
Page 39 and 40: z FIGURE 3 COAL REACTIVITY SCREENIN
Page 41 and 42: COPROCESSING USING HzS AS A PROMOTE
Page 43 and 44: - 3 - that product yields depend on
Page 45 and 46: - 5 - occurs in the yields of aspha
Page 47 and 48: Table 1 Analysis of Feedstocks Fore
Page 49 and 50: THO-STAGE COPROCESSING OF SUBBITUMI
Page 51 and 52: esult in retrogressive reactions ta
Page 53 and 54: 8. 6. Ignasiak, L. Lewkowicz, G. Ko
Page 55: Table 4 OVERALL MASS BALANCE FOR TH
Page 59 and 60: system, which could be operated wit
Page 61 and 62: TABLE 1 EFFECT OF LC-FINING~"' TEMP
Page 63 and 64: Figure 1. SCHEMATIC OF LCI CO-PROCE
Page 65 and 66: SIMULATION OF A COAL/PETROLEuII RES
Page 67 and 68: 20 pseudocomponents was developed t
Page 69 and 70: ottoms is less sensitive to the num
Page 71 and 72: Low Pressure Separator A temperatur
Page 73 and 74: 7. Gallier, P.W., Boston, J.F., Wu,
Page 75 and 76: I I I I I I I I I 100- --- Experime
Page 77 and 78: Coprocessing Schemes The coprocessi
Page 79 and 80: processing 25,000 and 150,000 bbl/d
Page 81 and 82: FIGURE 1 I DISTRIBUTION OF REFINERI
Page 83 and 84: Table 1. Samples Analyzed PNLNumber
Page 85 and 86: the coal itself. The chemical compo
Page 87 and 88: - - ITSL PAH Fraction PAH Fraction
Page 89 and 90: PROCESS DEVELOPMENT STUDIES OF TWO-
Page 91 and 92: SUMMARY e The major effect of close
Page 93 and 94: omw '??h 4NO WNID ?N? 000 wmm c9'1'
Page 95 and 96: tl f 246
Page 97 and 98: 248
Page 99 and 100: qkCqQ r! o! 0 0 0 0 0 0 0 I-UH ')I
Page 101 and 102: Materials The catalyst was shell 32
Page 103 and 104: CONCLUSIONS Separation of a light h
Page 105 and 106: Table 3. Results of activity testin
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feed coal and plant configuration a
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P1 #2 #3 114 115 #6 ITSL subbitumin
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temperature, time and solvent power
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TABLE 1 EXPERIMENTAL CONDITIONS AND
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la Figure 1. lH-NMR spectra of samp
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PERFORMANCE OF THE LOW TEMPERATURE
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BENCH UNIT DESCRIPTION Process deve
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Recycle Residuum Hydrogenati On Res
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FIRST STAGE HRI'S CATALYTIC TWO STA
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FIRST-STAQ COAL CONVERSION (W I IIA
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REACTOR SOLIOS HTOROGEN/CARBON ATOl
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TRANSPORTATION FUELS FROM TWO-STAGE
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Process Identification LV% Of AS- R
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Table I11 HYDROTREATING TESTS WITH
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Table IV HYDROTREATING TO 0.2 PPM N
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Table VI EFFECT OF BOILING RANGE ON
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(4) In all cases studied, the jet f
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292
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INTEGRATED TWO-STAGE LIQUEFACTION:
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are over-riding features in its fav
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Complementary fundamental studies o
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Comparative Economics of Two-Stage
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The variation in hydrotreating cost
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FIGURE 1: COMPARISONS OF ILLINOIS N
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Process TABLE 1: TWO-STAGE PROCESSE
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Abstract Temperature-Staged Catalyt
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Results and Discussion Reactions in
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2. 3. 4. 5. 6. Derbyshire, F. J. an
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I LL a rJJW ., .. ;> 0 i s W 8 a 31
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Materials Feeds to the WGS-solvent
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products. Thus, coupling the WGS an
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5. R. J. Xottenstette, Sandia Natio
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ENHANCED COAL LIQUEFACTION WITH STE
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change in weight being compared to
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I I aromatic ring. The group of sig
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T,\llI.l< I ASAI,YSIS OP \\YOl)Al\:
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00 3000 2000 le00 1600 1400 1200 IO
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THE EFFECT OF REACTION CONDITIONS O
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and may ultiontely form methyl-subs
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! 5. Narain, N.K., Utz, B.R., Appel
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4 (u I t + 9 (u I 337 - Q 0
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