Direct liquefaction proof-of-concept program. Finaltopical report, Bench Run 4 (227-95)

Abstract

This report presents the results of bench-scale work, Bench Run PB-04, conducted under the DOE Proof of Concept-Bench Option Program in direct coal liquefaction at Hydrocarbon Technologies, Inc. in Lawrenceville, New Jersey. The Bench Run PB-04 was the fifth of the nine runs planned in the POC Bench Option Contract between the U.S. DOE and Hydrocarbon Technologies, Inc. Bench Run PB-04 had multiple goals. These included the evaluation of the effects of dispersed slurry catalyst system on the performance of direct liquefaction of a subbituminous Wyoming Black Thunder mine coal under extinction recycle (454{degrees}C+ recycle) condition; another goal was to investigate the effects of the combined processing of automobile shredder residue (auto-fluff) with coal and other organic waste materials. PB-04 employed a two-stage, back-mixed, slurry reactor system with an interstage V/L separator and an in-line fixed-bed hydrotreater. The HTI`s newly modified P/Fe catalyst was very effective for direct liquefaction and coprocessing of Black Thunder mine subbituminous coal with Hondo resid and auto-fluff; during `coal-only` liquefaction mode, over 93% maf coal conversion was obtained with about 90% residuum conversion and as high as 67% light distillate (C{sub 4}-975 F) yield, while during `coprocessing` mode of operation, distillate yields varied between 58 and 69%; the residuum conversions varied between 74 and 89% maf. Overall, it is concluded, based upon the yield data available from PB-04, that auto-effective as MSW plastics in improving coal hydroconversion process performance. Auto-fluff did not increase light distillate yields nor decrease light gas make and chemical hydrogen consumption in coal liquefaction, as was observed to occur with MSW plastics.