Liquefaction of subbituminous coals with a basic nitrogenous model process solvent

Liquefaction reactions in a tubing-bomb reactor have been carried out as a function of coal, coal sampling source, reaction time, atmosphere, temperature, coal pre-treatment, SRC post-treatment and process solvent. Pyridine as well as toluene conversions ranging from 70 to > 90 wt% involving both eastern bituminous and western subbituminous coals are obtained. 1,2,3,4-Tetrahydroquinoline (THQ) has been extensively used as a process solvent under optimized liquefaction conditions of 2:1 solvent: coal, 7.5 MPa H₂, 691 K and 30 min reaction time. Comparisons of THQ with other model process solvents such as methylnaphthalene and tetralin are described. Liquefaction product yield for conversion of subbituminous coal is markedly decreased when surface water is removed from the coal by drying in vacuo at room temperature prior to liquefaction. The effect of mixing THQ with Wilsonville hydrogenated process solvent in the liquefaction of Wyodak and Indiana V coals is described.     

Liquefaction of partially dried and oxidized coals: 2. Coal characteristics

Samples of Belle Ayr (WY) subbituminous and Powhatan No. 5 mine (Pittsburgh Seam) bituminous coals were dried with gases including nitrogen, air and nitrogen/air mixture at temperatures essentially from ambient to 200 °C as part of a study to measure liquefaction behaviour. While the oxygen uptake of the subbituminous coal was up to 3 wt% and that of the bituminous coal was up to 8 wt%, the physical and chemical characteristics of both coals appeared to undergo only minor changes during treatment. However, CPAA oxygen analysis showed an apparent reaction of water with the coal, and FT—i.r. spectral results showed the formation of carbonyls and carboxylic acids with an indication of the formation of ethers.     

Effect of Wyodak coal properties on hydroliquefaction reactivity

The effect of Wyodak coal properties on liquefaction reactivity as measured by distillate yield and cyclohexane conversion has been investigated. Spot samples of four Wyodak subbituminous coals from the Anderson and Canyon coal seams in the Powder River Basin of NE Wyoming were liquefied in microautoclave and batch reactor experiments. Runs were made using two different Wyodak coal-derived solvents. Emphasis in this work was directed toward correlation of C₄-700 K distillate yield and cyclohexane conversion as functions of measurable physical, chemical and petrographic properties of the feed coal. Reactivity rankings were found to be the same using either measure of coal reactivity. However, the data indicated that distillate yields were a function of both solvent quality and feed coal properties. For each solvent studied, selected coal properties, including carbon content, total and organic sulphur content, vitrinite content and total reactive maceral (vitrinite plus exinite) content, were found to give statistically significant correlations with distillate production and cyclohexane conversion. Pyritic and sulphate sulphur contents did not appear to enhance liquefaction yield or conversion at the reaction conditions studied. However, any catalytic effects due to pyrite or sulphate sulphur may have been masked by the use of two high quality liquefaction solvents.     

Effect of NaOH treatment on surface properties of coal

Surface properties of sub-bituminous Wyodak and bituminous Illinois coals were examined using sorption and immersion techniques, to elucidate the effects of aqueous NaOH treatment. Sorption of non-polar gases such as CO₂ and N₂ decreased significantly after the alkali treatment for the Wyodak coal; however, similar tests with the Illinois coal did not produce such dramatic results. Water sorption and heats of immersion into liquid water increased considerably for both coals following the NaOH treatment. It is concluded that treatment with aqueous NaOH affects the chemical and physical structure of the coal surface.     

High temperature swelling of coal/tetralin mixtures in a high pressure microdilatometer

High pressure microdilatometer experiments were performed on a subbituminous (Wyodak) and a bituminous (Illinois no. 6) coal in helium and hydrogen atmospheres with and without added tetralin. Wyodak coal samples showed no swelling but contractions ranging between 24 and 40 vol% upon heating at 20 and 100 °C min^{− 1} under helium or hydrogen pressures between 150 and 1000 psig (˜1.0–6.9 MPa). Under the same conditions, Illinois no. 6 coals displayed contractions (25–60 vol%) prior to swelling up to 117 vol%. Upon tetralin addition (at 35–190 wt% of the coal), Wyodak coal samples did not swell but showed an increasing contraction with increasing helium or hydrogen pressure due to a slight softening and fusion of the coal particles. In contrast, addition of tetralin at much lower concentrations (5–35 wt%) had a marked effect on the contraction and swelling behaviour of Illinois no. 6. A maximum swelling of 200 vol% was obtained at a tetralin addition of 30 wt%. The increased swelling results from more extensive softening and fusion of coal particles in the presence of tetralin. Both coals showed a decreasing char yield with increasing tetralin concentration. The substantially lower extent of interaction observed between Wyodak coal samples and tetralin compared to Illinois no. 6 coal can be attributed to the differences in pore structure and/or chemical constitution of the two coal samples. Examination of the resultant solids by optical microscopy revealed the microstructural changes produced by thermal treatment in dilatometer experiments.     

Effect of coal liquefaction conditions on the trace element content of the soluble non-volatile product

Analysis of 18 trace elements via inductively coupled plasma atomic emission spectrometry has been performed on ‘in-house’ coal-derived non-volatile products. Analyses were conducted in a pyridine matrix to determine the effect of various conversion parameters on metal content. Four subbituminous coals (Wyodak 1–4) and one bituminous coal (Indiana V) were employed in conjunction with both non-basic (tetralin) and basic (1,2,3,4-tetrahydroquinoline) model process solvents. Trace metal data on solvent-refined coals as a function of feed coal, process solvent, reaction time, reaction temperature and extraction solvent are reported. Few trends in metal concentration are apparent on changing various liquefaction parameters. Metal concentrations are, however, approximately one to two orders of magnitude higher in pyridine soluble SRC relative to toluene soluble SRC. The majority of soluble metals, it is therefore suggested, are in the form of coordination complexes rather than true organometallics in SRC. Information regarding the effective molecular size of metal-containing species has been obtained via size exclusion chromatography with specific metal detection. Subtle changes are observed in the effective molecular size of metal-containing materials using different liquefaction parameters. For example, a greater fraction of each metal appears to be bonded to larger ‘sized’ molecules in pyridine soluble fractions than in toluene soluble fractions.     

Chemical structure of Wyodak coal

The chemical structure of a sub-bituminous coal from the Wyodak seam, Wyoming, has been investigated using the technique of per TFA oxidative degradation. The relative amounts of products differ markedly from those from a typical bituminous coal (Illinois No. 6 seam, Monterey mine).     

Liquefaction of partially dried and oxidized coals: 3. Liquefaction results

Samples of partially dried and oxidized Belle Ayr subbituminous coal were liquefied in a recycle donor solvent (SRC-ll heavy distillate) to observe the effect of coal pretreatment on conversion. Because subbituminous coals have moisture contents typically > 25%, it would appear useful to dry these coals prior to liquefaction; however, the drying of Belle Ayr coal, either in nitrogen or oxygen-containing gases, resulted in a significant decrease in yields of liquefied coal products. The liquefaction residues recovered from these runs were examined by optical microscopy and were found to contain high levels of coke. This coke appeared to have formed by polymerization of coal-derived liquid products.     

Role and composition of the mobile phase in coal

Extraction of Pittsburgh and Illinois No. 6 coals with tetrahydrofuran to remove a significant proportion of the mobile phase resulted in the elimination of thermoplastic properties. Cocarbonization of these extracted residues with large polycondensed aromatic molecules such as decacyclene and coronene resulted in the restoration of thermoplastic properties. It is proposed that large thermally stable aromatic molecules can perform a similar role to the molecular entities present in the mobile phase of bituminous coals, and that the presence of hydroaromatic (hydrogen donor) species in the mobile phase is unnecessary for the development of thermoplastic properties. The ability of thermally stable polycondensed aromatics to confer thermoplastic properties to coal appears to be related either to their hydrogen shuttling or radical stabilization propensity. The amounts and chemical nature of extracts from four coals (lignitic to high-volatile bituminous) were investigated. With increasing rank, the yields, aromaticity and degree of ring condensation of the extract (the mobile phase) all increased. For the two bituminous coals studied, the majority of the mobile phase was shown to consist of these thermally stable polycondensed aromatic species.     

Reactivity of hydrolysed coals in liquefaction

A hvA bituminous, a subbituminous and a lignite coal have been hydrolysed by 20–30% aqueous caustic solution at 100–300 °C and total pressure from ambient to 8.3 MPa (1200 psi). Reactivity of these pretreated coals toward liquefaction has been examined. The conversion to benzene-soluble material (BS) and oil increases, and the preasphaltene and char residue decreases after pretreatment. Improvement in the conversion to the BS fraction is only marginal for the pretreated bituminous coal, but substantial for the low-rank coals. For the subbituminous coal, the liquefaction reactivity (conversion to BS) increases with the severity of hydrolysis pretreatment. Analyses of chemical compositions, ¹H n.m.r. nuclei distributions and hydroxyl concentrations of the acid-insoluble hydrolysis coal extracts indicate that both O and S are enriched in the extracts with half of the oxygen atoms being in hydroxyl forms. The hydroxyl concentrations of the extracts (acid-insoluble) are ≈2 to 3 times higher than their parent coals. Coal activation by this alkali pretreatment is explained by the hydrolytic attacks on ether C–O linkages, and the removal of some constituents rich in oxygen functional groups which are responsible for poor liquefaction behaviour.     

Effects of sulfur on coal treatment in aqueous sodium hydroxide

The dissolution of Wyodak subbituminous and North Dakota lignite coals in 50% aqueous sodium hydroxide was enhanced by the addition of sulfur. The added sulfur was not incorporated into the undissolved coal residues. The effects of temperature (140–200°C), time (5–90 min), and added elemental sulfur (1–25% by weight) on dissolution were examined. Temperature affected the dissolution of subbituminous and lignite coal, while time affected the dissolution of subbituminous coal.     

Conversion of non-coking coals to coking coals by thermal hydrogenation

Coking properties are observed in four non-coking coals, a lignite, a subbituminous coal, a semianthracite and an oxidized bituminous coal which had been treated by partial thermal hydrogenation. The effects of temperature, reaction time and hydrogen pressure on liquid and solid product yields are examined. Microscopic examination of the hydrogenated solid residues shows that they all contain structures somewhat spherical in shape which are associated with mesophase development. The dilatation, plastic character and free swelling index of the hydrogenated solid products were considerably better than those of the original coals. Dilatation residues produced from hydrogenated solids exhibited anisotropic structures.     

Effects of solvent and iron-compounds on the liquefaction of brown coal

Hydrogen-donor solvents such as hydrophenanthrene are the most effective aromatic solvents for the liquefaction of brown coal. The hydrogen-donating ability of the solvent is more important for brown coals than for bituminous coals, because the thermal decomposition and subsequent recombination of the structure of the brown coals occurs rapidly. Three-ring aromatic hydrocarbons are more effective solvents than two-ring aromatics, and polar compounds are less effective solvents with brown coals than with bituminous coals. The thermal treatment of brown coal, accompanied by carbon dioxide evolution at temperatures > 300°C, in the presence of hydrogen-donating solvent did not affect the subsequent liquefaction reaction. However, thermal treatment in the absence of solvent strongly suppressed the liquefaction reaction, suggesting that the carbonization reaction occurred after the decarboxylation reaction in the absence of hydrogen donor. To study the effect of various iron compounds, brown coal and its THF-soluble fraction were hydrogenated at 450°C in the presence of ferrocene or iron oxide. The conversion of coal and the yield of degradation products are increased by the addition of the iron compounds, particularly ferrocene, and the yield of carbonaceous materials is decreased.     

Stability of some coal and tar sands syncrude fractions

Three fractions from a SRC-II coal liquefaction process, two naphthas from Illinois No. 6 coal and Wyodak coal using the Exxon Donor Solvent liquefaction process, and three fractions from tar sands extract were characterized for physical and chemical properties. Selected samples of syncrudes were stored at 43 °C for 32 weeks in air. The tar sands materials more closely resembled the properties of present petroleum-based materials, whereas the coal-derived liquids from the SRC-II process demonstrated the need for considerable upgrading. Heavier fractions seemed to undergo polymerization to produce gums, whereas lighter fractions deteriorated via oxidation.     

Additive effect of cobalt-exchanged coal on the liquefaction of subbituminous coal

In comparison with the liquefaction (420 °C, with tetralin and elemental sulfur) of the proton-exchanged Adaro subbituminous coal with complex (metallocene or metal carbonyl) of cobalt, nickel or iron, the coal liquefaction was enhanced significantly on the liquefaction of cation (Co²⁺, Ni²⁺ or Fe²⁺) exchanged Adaro coal. However, for several kinds of subbituminous coal, metal cations hardly exchange due to the small content of carboxyl group in coal. Therefore, the simultaneous liquefaction of subbituminous coal and cobalt-exchanged coal were carried out in this study. Further, the simultaneous liquefaction of lower rank and subbituminous coals with Co₂(CO)₈ was carried out to compare the catalytic effect of cobalt derived from either the exchanged coal or Co₂(CO)₈. The catalytic effect of cobalt in the exchanged Morwell brown coal was appeared as the decrease of residue yield on the liquefaction with Yilan subbituminous coal. On the other hand, there was little enhancement on the simultaneous liquefaction of cobalt-exchanged Adaro and Yilan subbituminous coals. Accordingly, it is clarified that the hydroliquefaction of subbituminous coal, which was exchanged cation hardly, was enhanced by the addition of cobalt-exchanged brown coal.     

Iron/sulfur-catalyzed coal liquefaction in the presence of alcohol and carbon monoxide

The activities of several iron-based catalyst precursors towards the liquefaction of various kinds of coals, ranging from brown to bituminous, were examined in alcohol–carbon monoxide systems. Pentacarbonyliron (Fe(CO)₅) with or without sulfur, or synthetic pyrite were found to be excellent catalyst precursors. Primary alcohols (ethanol and 1-propanol)–CO acted as an effective hydrogen source, whereas branched alcohols were less effective. In the Fe(CO)₅/sulfur catalyzed liquefaction of Yallourn coal at 375°C for 120 min, a high conversion (99.5%) was achieved in the presence of ethanol and CO (7.0 MPa/cold). The two-staged reaction (375°C, 60 min+425°C, 60 min) further improved the oil yield to 59.1% with a slight decrease in the coal conversion. The uptake of alcohol into asphaltene and preasphaltene fractions was distinctly observed, especially for Illinois No. 6 coal. The infrared analyses of the asphaltene fractions from each coal showed absorption at around 1705 cm⁻¹, characteristic for those obtained in the linear alcohol–CO systems. According to the characterization of the products by NMR and the preliminary study using a model compound, alkylation as well as the hydrogenolysis seem to contribute to the dissolution of coals.     

Kinetics of thermal liquefaction of coal

A model is presented for the kinetic study of the thermal liquefaction of Belle Ayr subbituminous and Burning Star bituminous coals with anthracene oil, hydrogenated anthracene oil and hydrogenated phenanthrene. All experiments were performed in a continuous-feed, stirred tank reactor, at a temperature of 450 °C and a space time of approximately 5 to 55 min. A kinetic model which includes a reaction: coal + oil→more reactive coal, correlates the data reasonably well. This reaction explains the net consumption of anthracene oil during the initial stages of liquefaction. Such a reaction may account for a portion of the swelling of coal at low space times and the sizable increase of viscosity of reaction slurry during these initial stages of liquefaction. It is also observed that the yield of oil increases when solvents of increasing hydrogen donor capacity are used.     

Interrelationship of chemical characterization and rheological behaviour of coal liquefaction bottoms

In the development of the Exxon Donor Solvent (EDS) process, bituminous and subbituminous coals have been processed in a one ton-per-day coal liquefaction pilot plant using the feed coal slurried with solvent and with or without bottoms recycle. The liquefaction bottoms from both once-through and bottoms recycle operation exhibit non-Newtonian viscometric behaviour. The recycled bottoms, however, are more viscosity/shear dependent, less viscosity/temperature dependent and more thermally stable than the once-through bottoms. Chemical characterization of these bottoms reveals that alkyl and phenoxy groups are important functional groups responsible for the viscometric behaviour of bottoms. The increase of bottoms viscosity is postulated to involve the elimination/condensation of methylene units are phenolic functional groups to form the crosslinkages of large aromatic clusters.     

Effect of oxidation on the chemical nature and distribution of low-temperature pyrolysis products from bituminous coal

Two bituminous coals, a high volatile Eastern Canadian and a medium volatile Western Canadian, were used to investigate the effect of oxidation on yields and chemical composition of gases, liquids and chars produced during coal pyrolysis. Pyrolysis experiments were performed at 500 °C using the Fischer assay method. Mild oxidation of coals resulted in a decrease of liquid hydrocarbon yields. Further coal oxidation increased the proportion of aromatic carbon in liquid products as determined by n.m.r., and also increased the content of oxygen in liquid products. The content of oxygen in chars was markedly lower than in corresponding coals. An attempt is made to explain reactions occurring during oxidation and subsequent pyrolysis of coal on the basis of differences in chemical composition of gases, liquids and chars.     

A newly proposed view on coal molecular structure integrating two concepts: Two phase and uniphase models

Concept of coal molecular structure was reexamined on the basis of detailed information concerning aliphatic moieties of coal and the reactions occurred during coalification process. Based on the observed similarity of the distribution of chain length between alkylene bridge bonds and alkyl pendant groups on coal aromatic cluster, the authors have already proposed [Nomura, M., Murata, S., Kidena, K. 2004a. Some view on the solubilities of coals toward solvents. Proceedings of 21st Annual International Pittsburgh Coal Conference, No. 12-4.] the presence of common intermediates in the coalification process which results in uniphase structure under reductive conditions and two phase structure under oxidative conditions, respectively. The present paper proposes, the concept that the reactivity of the coal aromatic moieties for common intermediates and/or the stability of common intermediates govern the reactions leading to a two phase structure or uniphase structure in more rationalized way as coalification is believed to proceed under reductive conditions, especially at its late stage. Brown and subbituminous coals have relatively many oxygen-containing functionalities on aromatic moieties so that their aromatic rings are activated for radical reactions. Common intermediate radicals, aryl alkyl radicals, from cleavage of alkyl pendant groups on aromatic rings and alkylene bridge bonds attack neighboring aromatics to form entanglement-like structure in an easy way. These structures are less soluble to organic solvents due to its entanglement character. Bituminous coals with high solubility toward CS₂/NMP solvents tend to have carbon contents from 85 to 87% (daf. basis), their aromatic moieties being so stable that intermediate radicals cited above can attack more selectively the neighboring aromatic moieties: they have less tendency to make such bridge bonds to form cross linked structures, the resulting coal molecules being not entangled like uniphase. In the case of coals having more carbon than 87% or bituminous coals with less carbon than 85%, the resulting coal molecules become less soluble toward organic solvents: In the higher rank coals, the aromatic rings are so large and so stable that their solubility toward solvent are intrinsically low. In addition to this, it is supposed that bridge bonds are cleaved to make the structure with less cross linking. Their stacking tendency should be also considered as other reason for low solubility to solvent. On the other hand, less solubility of the lower ranked bituminous coals can be rationalized partly, in an analogy with the behavior that the brown and subbituminous coals show, despite of their relatively large aromatic clusters.