Liquefaction of Yallourn brown coal at low pressures and rapid heating rates

Liquefaction of Yallourn brown coal in solvents at high temperature for short contact times and low pressures has been studied. Very high asphaltene yields are achieved with hydrogen-donating solvents (hydrogenated Ashland pitch A240, hydrogenated anthracene oil, and hydrogenated pyrene). For hydrogenated pyrene, yields of almost 90% were obtained during reaction at 450°C for 10 min or at 510°C for 1 min. The average molecular weight of the asphaltene found was 270, with 40 wt% being accounted for by three-and four-ring polynuclear hydrocarbons. The effect of liquefaction temperature, time, and solvents on the asphaltene yield have been examined to clarify the properties required for the solvent under the present conditions used. The behaviour of the asphaltene during pyrolysis and hydrotreatment has also been studied. Some mechanistic aspects of high-temperature, short contact time liquefaction are discussed with regard to the reactivities of the brown coal and the solvents.     

Solvolytic liquefaction of coals with a series of solvents

Solvolytic liquefaction of coals of different rank was studied with a variety of solvents at 370–390 °C under nitrogen in order to elucidate the role of solvent in coal liquefaction of this kind and to find a suitable solvent for the highest yields of liquefaction. The yield was found to depend strongly upon the nature of the coal as well as the solvent under these conditions. Pyrene and a SRC-BS pitch were excellent solvents for Miike coal, which was fusible with high fluidity at these temperatures. However, the former was less efficient for Itmann and Taiheiyō coals which were fusible at a higher temperature and non-fusible, respectively. The mechanism of solvolytic liquefaction is discussed, including nature of coal and solvent at reaction temperatures, in order to understand the properties required for high yields with non-fusible coals in solvolytic liquefaction. It is found that for liquefaction with a high yield if the coal is non-fusible, solvolytic reaction should take place between solvent and coal, so giving a liquid phase of low viscosity at the reaction temperature. The solvolytic reaction may be one of hydrogen transfer when SRC-BS is used as the solvent.     

Liquefaction of subbituminous coals under apparently non-hydrogenative conditions

Reactivities of several coals of different ranks have been examined in degrading extractions with aromatic solvents under apparently non-hydrogenative reaction conditions. Pyrene and A240 pitch liquefied the fusible coals in high yields and the slightly-fusible coals in moderate yields, indicating the importance of fusibility in such liquefaction processes. A240-LS pitch is a powerful solvent for slightly-fusible coals. Considerable amounts of pyridine- or THF-soluble fractions were produced especially with A240-LS pitch. A240 pitch is a better solvent than pyrene for some slightly-fusible coals. However, the extent of depolymerization of liquefied coal, pyridine- or THF-solubility, was definitely inferior. Yields of such fractions are higher for lower-rank coals. The mechanism of coal liquefaction under apparently non-hydrogenative conditions is discussed with emphasis on the stabilization of thermal fragments derived from the coal.     

Relative reactivity of hydrogen donor solvent in coal liquefaction

Hydrogen transfer from donor solvent to coal must involve reactions such as hydrogen donation to free radicals and hydrogenation of aromatic structures. The relative reactivities of five typical hydrogen donor solvents, more reactive than tetralin, were determined using a competing elimination reaction in the liquefaction of a bituminous coal at 400 °C and a brown coal at 350 °C. 9,10-Dihydroanthracene, 9,10-dihydrophenanthrene and 1,2,3,4-tetrahydroquinoline exhibited outstanding hydrogen donating ability. Further, the relative reactivities of five mild hydrogen donor solvents such as acenaphthene and indan were determined by a similar elimination reaction using a bituminous coal at 450 °C.     

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.     

Effect of pre-swelling of coal on its solvent extraction and liquefaction properties

Effects of pre-swelling of coal on solvent extraction and liquefaction properties were studied with Shenhua coal. It was found that pre-swelling treatments of the coal in three solvents, i.e., toluene (TOL), N-methyl-2-pyrrolidinone (NMP) and tetralin (THN) increased its extraction yield and liquefaction conversion, and differed the liquefied product distributions. The pre-swollen coals after removing the swelling solvents showed increased conversion in liquefaction compared with that of the swollen coals in the presence of swelling solvents. It was also found that the yields of (oil + gas) in liquefaction of the pre-swollen coals with NMP and TOL dramatically decreased in the presence of swelling solvent. TG and FTIR analyses of the raw coal, the swollen coals and the liquefied products were carried out in order to investigate the mechanism governing the effects of pre-swelling treatment on coal extraction and liquefaction. The results showed that the swelling pre-treatment could disrupt some non-covalent interactions of the coal molecules, relax its network structure and loosened the coal structure. It would thus benefit diffusion of a hydrogen donor solvent into the coal structure during liquefaction, and also enhance the hydrogen donating ability of the hydrogen-rich species derived from the coal.     

Action of solvents on coal at low temperatures: 1. Low-rank coals

The dissolution behaviour of brown coals (67–75% C, daf) in pyridine, primary amines and aqueous KOH has been studied. The solubility in the last two solvents greatly depends on temperature, but in the first it is relatively temperature-independent. Pretreatment of the brown coals with aqueous HCl or with sodium ethanolate in ethanol leads to enhanced solubility. It is concluded that ester-bond breaking is necessary before extensive dissolution can take place. The solubility of brown coals in amines and aqueous KOH is found to increase with increasing carboxylic-acid group concentration in the coal. The solubility of Morwell brown coal in n-alkylamines at 180 °C increases with increasing length of the alkylchain in the solvent. The class of good solvents for brown coals is restricted to strong bases, because: 1. ester bonds have to be broken, 2. the acidic coal fragments have to be solubilized. Because of their capacity to break ester bonds these are so-called reactive solvents. Complete solvent recovery is impossible in the case of amines.     

Efficiency of hydrogen transferring liquefaction of a subbituminous coal using hydrogenated fluoranthene for short contact time at high temperature and low pressure

An Australian subbituminous coal (Wandoan) was effectively liquefied at 490 and 510 °C under nitrogen pressure of 2.5 MPa for 1.0–7.5 min using 1, 2, 3, 3a-tetrahydrofluoranthene (4HFL) as a hydrogen-donating solvent. The yields of oil and asphalthene could be as high as 58 and 24 wt%, respectively. The content of 4HFL was very influential on the oil yield although under appropriate liquefaction conditions, a considerable amount remained after reaction. The kinetics of the reaction and analytical study of the products and the solvent suggest consecutive as well as instantaneous depolymerization in the process. The coking or recondensation reaction was very rapid after 4HFL was consumed, confirming the efficacy of the short contact time liquefaction.     

Effect of coal minerals on the thermal treatment of aromatic ethers and carbonyl compounds

To elucidate the effect of mineral matter in coal on coal liquefaction, the thermal decomposition of some model compounds of coal structure, aromatic ethers and carbonyl compounds, has been carried out in tetralin solvent and in the presence of coal ash obtained by low temperature combustion. The conversion of benzyl phenyl ether and dibenzyl ether was considerably enhanced; alkylated products such as benzyltetralin were obtained. The conversion of phenoxyphenanthrene and phenoxynaphthalene also was increased to some extent in the presence of coal ash. These effects can be attributed to the acidic components of coal minerals, because silica-alumina has shown the same effect, which is suppressed by quinoline. The addition of coal ash increases the yield of hydrocarbon from the corresponding aromatic carbonyl compounds by reduction. This effect is attributable to iron sulphide.     

The effect of extraction condition on ‘HyperCoal’ production (1)—under room-temperature filtration

In order to produce ashless coal (HyperCoal) in a high yield, extractions with several organic solvents—tetralin, 1-methylnaphthalene, dimethylnaphthalene and light cycle oil (LCO) at 200–380 °C were conducted for various ranks of coals, and subsequent solid/solution separation was done at room temperature. LCO was found to be a useful, cost-effective solvent, since it gave similar extraction yields to three other reagent solvents. The extraction yield for Illinois No. 6 coal gradually increased over 200 °C, and a significant increase in extraction yield was observed from 350 to 360 °C. We succeeded in producing ashless coal with less than 0.1% in ash content for seven of nine coals used in this study.     

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.     

Mechanisms leading to process improvements in lignite liquefaction using CO and H2S

Optimum distillate yields from US lignites can be as high on a dry, ash-free basis as those obtained from bituminous coals, but only if the vacuum bottoms are recycled. Lignites are more readily liquefied if the reducing gas contains some carbon monoxide and water, which together with bottoms recycle has proven to yield the highest conversions and the best bench-unit operability. The recycle solvent in the reported tests consisted of unseparated product slurry, including coal mineral constituents. Variability in coal minerals among nine widely representative US low-rank coals did not appear to correlate with liquefaction behaviour. Addition of iron pyrite did, however, improve yields and product quality, as measured by hydrogen-to-carbon ratio. Future improvements in liquefaction processes for lignite must maintain high liquid yields at reduced levels of temperature, pressure, and reaction time whilst using less reductant, preferably in the form of synthesis gas (CO + H₂) and water instead of the more expensive pure hydrogen. Understanding the process chemistry of carbon monoxide and sulphur (including H₂S) during lignite liquefaction is a key factor in accomplishing these improvements. This Paper reviews proposed mechanisms for such reactions from the viewpoint of their relative importance in affecting process improvements. The alkali formate mechanism first proposed to explain the reduction by CO does not adequately explain its role in lignite liquefaction. Other possible mechanisms include an isoformate intermediate, a formic acid intermediate, a carbon monoxide radical anion, direct reaction with lignite, and the activation of CO by alkali and alkaline earth cations and by hydrogen sulphide. Hydrogen sulphide reacts with model compounds which represent key bond types in low-rank coal in the following ways: (1) hydrocracking; (2) hydrogen donor; (3) insertion reactions in aromatic rings; (4) hydrogen abstraction, with elemental sulphur as a reaction intermediate; and (5) catalysis of the water-gas shift reaction. It appears that all of these reaction pathways may be operative when catalytic amounts of H₂S are added during liquefaction of lignite. In bench recycle tests, the addition of H₂S as a homogeneous catalyst reduced reductant consumption as much as three-fold whilst maintaining high yield levels when the reaction temperature was reduced by 60°C. Attainment of the high distillate yield at 400°C was accompanied by a marked decrease in the production of hydrocarbon gases, which normally is a major cause of unproductive hydrogen consumption and solvent degradation via hydrocracking. Processing with synthesis gas and inherent coal moisture using bottoms recycle and H₂S as a catalyst appears to be the most promising alternative combination of conditions for producing liquids from lignite at reduced cost.     

Fractionation of coal by use of high temperature solvent extraction technique and characterization of the fractions

The authors have recently presented a new coal fractionation method that can separate a bituminous coal into several fractions, just like petroleum distillation, without decomposing coal. In this paper this method was applied to two bituminous coals and a brown coal. Sequential solvent extraction at different temperatures lower than 350 °C successfully separated the two bituminous coals into several fractions having different molecular mass compounds. Since all the extracted fractions are almost free from mineral matter, and some fractions were found to be fusible like a synthesized pitch when heated, the possibility of producing high performance carbon materials from the coal fractions was investigated. On the other hand, fractions obtained from the brown coal by the sequential solvent extraction were very close in both chemical composition and molecular mass, although the sequential extraction could greatly suppress the decomposition of the brown coal below 350 °C. The difference in the extraction behavior between the bituminous coals and the brown coal were attributed to the difference in their chemical structure.     

煤直接液化溶剂油的平均结构

对一种褐煤的直接液化加氢前、后溶剂油进行了1H核磁共振波谱、元素组成和分子量等性质的分析和平均结构参数的计算,研究了加氢前、后溶剂油分子的平均结构。结果显示：加氢处理前、后溶剂油的平均分子式为C17H23S0.004N0.09O0.12和C16H24S0.003N0.03O0.03,加氢前溶剂平均分子的芳碳率fa为0.46,平均分子结构含有2～3个环,其中芳香环为1～2个,环烷环为1个。经过加氢处理后溶剂油分子的平均结构发生较大的变化,溶剂平均分子芳碳率fa为0.37,平均分子结构中含有2个环,其中芳香环1个,环烷环1个,经加氢处理后,溶剂具备了较好的供氢性能。     

Mössbauer study of iron catalysis in Victorian brown coal liquefaction

Mössbauer spectroscopy was used to investigate the means by which iron promotes the hydroliquefaction of Victorian brown coal. Microparticulate ferric oxyhydroxide incorporated in the initial coal is reduced during hydrogenation through magnetite and troilite to α-iron, which transforms to cementite at 380 °C. It is proposed that a transient divalent iron species slows the initial thermal degradation of coal and that α-Fe is responsible for enhancing the ultimate liquefaction yield.     

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.     

Comparison of anthracene and phenanthrene in coal liquefaction

A comparison of anthracene and phenanthrene as solvents was undertaken by liquefying either Wyodak or Kentucky 9/14 coal in the presence of hydrogen or nitrogen. Phenanthrene was found to be a better physical solvent than anthracene for liquefying both coals. Anthracene and its derivatives are better hydrogen-shuttling solvents than phenanthrene and its derivatives. Hydrogenation of anthracene to tetrahydro-anthracene was observed with both coals. Dihydroanthracene is a better hydrogen-shuttling solvent than dihydrophenanthrane in the liquefaction of Kentucky 9/14 coal. Anthracene is a better solvent than phenanthrene in the presence of 1-methylnaphthalene in liquefying both Wyodak coal under hydrogen and Kentucky 9/14 coal under nitrogen. The minerals in Kentucky 9/14 coal appear to be better hydrogenation catalysts than those in Wyodak coal. Labile hydrogen from coal appears to escape readily before reacting with hydrogen-shuttling solvents under the atmospheric environment.     

Synergistic effects between light and heavy solvent components during coal liquefaction

As part of research to examine coal conversion in solvents containing high-boiling-point components, experimental studies were carried out with model compound solvents. The dissolution of bituminous and subbituminous coals was investigated in pyrene-tetralin and 2-methylnaphthalene-tetralin mixtures. The effects of donor level, gas atmosphere, hydrogen pressure and conversion temperature were determined. At 400 °C, in the presence of hydrogen gas, pyrene-tetralin solvent mixtures show synergism in coal conversion. At donor concentrations as low at 15 wt%, the degree of conversion was almost as high as in pure tetralin. This phenomenon was not apparent in 2-methylnaphthalene-tetralin mixtures. The relative ease of reduction of pyrene and its ability to shuttle hydrogen is considered to be a principal reason for this difference in behaviour. Conversion in pure pyrene and in pyrene-tetralin mixtures at low donor concentrations increased with increasing hydrogen pressure. At 427 °C, bituminous coal conversion was higher in a 30 wt% tetralin-70 wt% pyrene mixture than in either pure compound. It was found that in the absence of coal pyrene can be hydrogenated by H-transfer from tetralin as well as by reaction with hydrogen gas. This can provide a means to increase the rate of transfer of hydrogen to the dissolving coal through the formation of a very active donor (dihydropyrene). During coal liquefaction, several pathways appear to be available for hydrogen transfer for a given coal, the optimal route being dependent upon the solvent composition and the conditions of reaction.     

A kinetic investigation of coal liquefaction at short reaction times

Coal liquefaction kinetics have been studied at very short reaction times (less than 250 seconds) in order to emphasize the initial underlying physical and chemical processes involved. These studies were made possible by the use of a continuous flow stirred tank reactor (CSTR) which avoids the problems of slow heat up and cool down associated with the massive equipment required for running high-temperature and high-pressure liquefaction reactions. Preliminary physical (NMR and ESR) and chemical analytical results are presented on the coal liquids and reaction residues from Illinois No. 6 hv bituminous and Wyodak Black Thunder subbituminous coals.

ESR results showed that radical concentration in the solid residue changed during coal liquefaction. These changes were accompanied by changes in the NMR-derived aromaticity. The rate of decrease of organic-based radicals was different for Wyodak Black Thunder and Illinois No. 6 coals, perhaps indicating a different mechanism for the quenching of radicals in these bituminous and subbituminous coals. NMR spectra of the liquid products indicated that the initially produced material was relatively aromatic, and that subsequent products had lower aromatic content. This is consistent with secondary hydrogenation of the primary liquefaction products. Finally, the total oxygen contents of the coal residues decreased gradually during the first three minutes of coal liquefaction at 390°C. A corresponding decrease in the hydroxyl content of these residues was also noted.     

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.