Liquefaction of coals using ultra-fine particle, unsupported catalysts: In situ particle generation by rapid expansion of supercritical fluid solutions. Final technical report

Abstract

The research conducted by Textron Defense Systems (TDS) represents a potential new and innovative concept for dispersed coal liquefaction. The technical approach is generation of ultra-fine catalyst particles from supercritical solutions by rapid expansion of either catalyst only, or mixtures of catalyst and coal material in supersaturated solvents. The process of rapid expansion of supercritical fluid solutions was developed at Battelle`s Pacific Northwest Laboratories for the intended purpose of providing a new analytical technique for characterizing supercritical fluids. The concept forming the basis of this research is that ultra-fine particles can be generated from supercritical solutions by rapid expansion of either catalyst or catalyst/coal-material mixtures in supersaturated solvents, such as carbon dioxide or water. The focal point of this technique is the rapid transfer of low vapor pressure solute (i.e., catalyst), dissolved in the supercritical fluid solvent, to the gas phase as the solution is expanded through an orifice. The expansion process is characterized by highly nonequilibrium conditions which cause the solute to undergo extremely rapid supersaturation with respect to the solvent, leading to nucleation and particle growth resulting in nanometer size catalyst particles. A supercritical expansion system was designed and built by TDS at their Haverhill facility.