Liquefaction co-processing of coal shale oil at - Argonne National ...
Liquefaction co-processing of coal shale oil at - Argonne National ... Liquefaction co-processing of coal shale oil at - Argonne National ...
catalytic stage in Run 2506, whereas in Run 244 approximately 45 wt % was produced by the catalytic hydrotreater (Table 3). Higher quality products are made by the catalytic stage. Subsequent operation in CC-ITSL was devoted to study of performance of a new catalyst, Amocat 1C. As noted previously, interstage vapor separation was employed throughout this period. A comparison of "all-distillate'' operation at the same coal feed rate for Shell 324 and Amocat 1C revealed that distillate and hydrocarbon gas yields were similar (Run 2508 versus Run 250C). An alternate deashing solvent was used in Run 250C in order to maintain stable perfonnance while processing the highly soluble feed generated by the fresh Amocat catalyst. This resulted in greater rejection of resid to ash concentrate with concomitantly less TSL resid produced. A lower hydrogen consumption was observed for Run 250C. This phenomenon could be attributed to the effect of interstage separation (i.e., not hydrotreating all distillate products) and/or to relatively lower hydrogenation activity of the Amocat catalyst. Higher system space velocities were explored by increasing coal feed rates. The goal was to demonstrate the production of high quality (CC-ITSL) distillates at reduced cost. Yield data are reported for Run 250 Periods C, 0, and E in Table 1. Product quality data and unit contributions to distillate production for Period D are given in Tables 2 and 3, respectively. The data clearly indicate that "all-distillate'' yield slates were produced at increased throughputs by compensatory increases in reactor temperatures. Product quality did not change significantly at the higher rates. It should also be noted that products from higher space velocity CC-ITSL were substantially better than those from lower space velocity ITSL. Near the conclusion of Run 250, a test of solids (unconverted coal and ash-cresol insolu- bles) recycle was performed (Figure 3). The objective was to decrease size of the critical solvent deashing unit by deashing a higher solids content vacuum bottoms stream. Deashed resid was recycled as a component of the liquefaction solvent. Lower organic rejection to the ash concentrate was demonstrated with the concentrated feed. Based on this result, the concept of solids recycle may be investigated in a future close-coupled run using catalyst in both reactors. Batch deactivation trends for resid conversion in the catalytic reactor were developed for the ITSL (deashed bituminous)- Shell 324 and CC-ITSL (close-coupled bituminous)-Amocat 1C modes, using a first order resid conversion model (1). The trends are plotted in Figure 4 together with batch deactivation data from Wilsonville Run 247 ("simulated" close- coupled). The trends showed initial periods of rapid deactivation, followed by slower deactivation rates. Higher resid conversion rate constants were observed for close- coupled operation using the Amocat 1C catalyst. The close-coupled residlhocat combina- tion was more reactive than the other feedlcatalyst (Shell 324) combinations. Figure 5 further illustrates this point in an Arrhenius plot. RELATIVE ECONOMICS Results from an economic screening study performed by Lummus Crest Inc. indicated a reduction in the required product selling price for CC-ITSL products compared to ITSL products (Table 41. The study was based on a conceptual comnercial 10,000 TPD plant using Illinois No. 6 coal. The relatively lower price was due to higher distillate production and improved distillate quality for the close-coupled case (2). 241
SUMMARY e The major effect of close-coupled operatlon was an increase in hydrogen con- sumption with a corresponding improvement in distillate product quality. a At the same coal feed rate, C4+ distillate and hydrocarbon gas yields were similar for close-coupled operation with Shell 324 and Amocat 1C catalysts. A lower hydrogen consumption was observed in the Amocat operation. This phenome- non could be attributed to the effect of interstage separation and/or to the relatively lower hydrogenation activity of the Amocat catalyst. a "All-distillate'' yield slates were produced at higher system space velocities by compensatory increases in reactor temperatures. e Product quality was not significantly affected at higher system space veloci- ties. a Operating with solids recycle in the close-coupled mode, lower organic rejection to ash concentrate was demonstrated at a relative reduction in feed rate to the critical solvent deashing unft. a A comparison of resid conversion rate constants indicated that the close-coupled resid/Amocat 1C combination was more reactive than other feed/catalyst (Shell 324) combinations. a Results from an economic screening study for a conceptual commercial 10,000 TPD plant indicated a reduction in the required product selling price for CC-ITSL plant products compared to ITSL plant products. ACKNOWLEDGMENTS This work was supported by the U. S. Department of Energy under Contract DE-AC22-82PC50041, and by the Electric Power Research Institute under Contract RP1234-1-2. The author also gratefully appreciates the assistance of Ms. Joyce Spearman and Messrs. Bill Hollenack, Johnny Gill, and Dave Edwards. REFERENCES 1. Rao, A. K., Gadiyar, H. J., Pate, F. L., "Catalytic Hydrogenation of SRC-I Product at the Wilsonville Pilot Plant", Proceedings of the Seventh Annual EPRI Contractors Conference on Coal Liquefaction, May 1982. 2. Corrypondence from M. Peluso to W. Weber, "RP832-11, Final Technical and Economic Data , January 23, 1986. 242
- Page 39 and 40: z FIGURE 3 COAL REACTIVITY SCREENIN
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SUMMARY<br />
e The major effect <strong>of</strong> close-<strong>co</strong>upled oper<strong>at</strong>lon was an increase in hydrogen <strong>co</strong>n-<br />
sumption with a <strong>co</strong>rresponding improvement in distill<strong>at</strong>e product quality.<br />
a At the same <strong>co</strong>al feed r<strong>at</strong>e, C4+ distill<strong>at</strong>e and hydrocarbon gas yields were<br />
similar for close-<strong>co</strong>upled oper<strong>at</strong>ion with Shell 324 and Amoc<strong>at</strong> 1C c<strong>at</strong>alysts. A<br />
lower hydrogen <strong>co</strong>nsumption was observed in the Amoc<strong>at</strong> oper<strong>at</strong>ion. This phenome-<br />
non <strong>co</strong>uld be <strong>at</strong>tributed to the effect <strong>of</strong> interstage separ<strong>at</strong>ion and/or to the<br />
rel<strong>at</strong>ively lower hydrogen<strong>at</strong>ion activity <strong>of</strong> the Amoc<strong>at</strong> c<strong>at</strong>alyst.<br />
a<br />
"All-distill<strong>at</strong>e'' yield sl<strong>at</strong>es were produced <strong>at</strong> higher system space velocities by<br />
<strong>co</strong>mpens<strong>at</strong>ory increases in reactor temper<strong>at</strong>ures.<br />
e Product quality was not significantly affected <strong>at</strong> higher system space veloci-<br />
ties.<br />
a Oper<strong>at</strong>ing with solids recycle in the close-<strong>co</strong>upled mode, lower organic rejection<br />
to ash <strong>co</strong>ncentr<strong>at</strong>e was demonstr<strong>at</strong>ed <strong>at</strong> a rel<strong>at</strong>ive reduction in feed r<strong>at</strong>e to the<br />
critical solvent deashing unft.<br />
a<br />
A <strong>co</strong>mparison <strong>of</strong> resid <strong>co</strong>nversion r<strong>at</strong>e <strong>co</strong>nstants indic<strong>at</strong>ed th<strong>at</strong> the close-<strong>co</strong>upled<br />
resid/Amoc<strong>at</strong> 1C <strong>co</strong>mbin<strong>at</strong>ion was more reactive than other feed/c<strong>at</strong>alyst (Shell<br />
324) <strong>co</strong>mbin<strong>at</strong>ions.<br />
a Results from an e<strong>co</strong>nomic screening study for a <strong>co</strong>nceptual <strong>co</strong>mmercial 10,000 TPD<br />
plant indic<strong>at</strong>ed a reduction in the required product selling price for CC-ITSL<br />
plant products <strong>co</strong>mpared to ITSL plant products.<br />
ACKNOWLEDGMENTS<br />
This work was supported by the U. S. Department <strong>of</strong> Energy under Contract<br />
DE-AC22-82PC50041, and by the Electric Power Research Institute under Contract RP1234-1-2.<br />
The author also gr<strong>at</strong>efully appreci<strong>at</strong>es the assistance <strong>of</strong> Ms. Joyce Spearman and Messrs.<br />
Bill Hollenack, Johnny Gill, and Dave Edwards.<br />
REFERENCES<br />
1. Rao, A. K., Gadiyar, H. J., P<strong>at</strong>e, F. L., "C<strong>at</strong>alytic Hydrogen<strong>at</strong>ion <strong>of</strong> SRC-I Product <strong>at</strong><br />
the Wilsonville Pilot Plant", Proceedings <strong>of</strong> the Seventh Annual EPRI Contractors<br />
Conference on Coal <strong>Liquefaction</strong>, May 1982.<br />
2.<br />
Corrypondence from M. Peluso to W. Weber, "RP832-11, Final Technical and E<strong>co</strong>nomic<br />
D<strong>at</strong>a , January 23, 1986.<br />
242
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