MO- OR W-CATALYST FOR COAL EXTRACTION PROCESS

Abstract: A two stage coal extracting process has a first liquid hydrogen donor solvent oil extraction stage and a second stage comprising catalytic hydrocracking of the extract. Desired levels of hydrocracking and hydrogenation of the extract, with an acceptable level of naphthene formation, are achieved by using on the catalyst a mixture of a promoted W or Mo catalyst with an unpromoted W or Mo catalyst.

Description: This invention concerns a coal extraction process. More especially it concerns a liguid solvent extraction process incorporating a recycle of solvent after a hydrogenation stage. It is known to extract coal using a liquid hydrogen donor solvent oil, and to hydrocrack and/or hydrogenate the coal solution over a catalyst. Such a process may he termed a two-stage direct liquefaction, as opposed to a single stage liquefaction in which hydrogen is directly supplied to a coal-solvent slurry. The two-stage process generally shows increased yields of gasoline, aviation and diesel fuel fractions per unit of hydrogen consumed, compared to the single stage process. Part of the advantage held by the two-stage process derives from the use in the extraction stage of a recycle solvent rich in hydrogen donors, which stabilise by hydrogen transfer the free radicals formed by decomposition of the coal, and hence suppress recombination reactions and solvent adduction, leading to less hydrocarbon gas formation during hydrocracking. Our research work has shown that there is a tendency for the hydrocracking stage to result in over-hydrogenation of the solvent fraction, producing an undesired excess of naphthenes rather than hydrogen-donor hydroaromatics. This has several effects including a high consumption of expensive hydrogen and, importantly, the production of a recycle solvent containing naphthenes in such quantities that there is a tendency for high molecular weight or polar compounds to separate out of solution if the solution temperature falls. This may cause blockages in equipment. We have discussed these problems and disclosed methods of reducing the naphthene content of recycle solvents in our British Patent Nos. 2,156,841 and 2,191,211. The recommended catalysts for hydrocracking coal solutions are molybdenum sulphide or tungsten sulphide, promoted with nickel or cobalt, on a support, which may be an alumina, alumina-silicate, silica, active carbon, magnesia, chromia, titania, carbon etc., and many suitable catalysts are commercially available as sulphur-resistant hydrotreatment or hydrocracking catalysts for petroleum refining. We have now found a novel method of carrying out a two-stage coal liquefaction process, comprising a coal with a liquid hydrogen donor solvent at elevated temperature and pressure, catalytically hydrocracking at least a portion of the extract and at least a portion of the solvent and recycling as solvent a fraction of the hydrocracked product, characterised in that the hydrocracking catalyst is a mixture of a promoted tungsten or molybdenum sulphide catalyst and an unpromoted catalyst, the promoted catalyst being present in an amount of from 5 to 20% by vol of the total catalyst, the promoted catalyst having tungsten or molybdenum present at loadings of from 1 to 30% by weight, calculated as the oxide and the promoter heing present at loadings of 0.1 to 5%, calculated as the oxide. The invention further provides a mixed catalyst for use in the method. We have found that the present invention enables the extract and solvent to he subjected to the desired extents of both hydrocracking and hydrogenation thereby controlling the formation of napthenes to acceptable levels, whilst achieving the desired product yields. It can readily he seen that the invention offers a less expensive method of controlling naphthene contents than methods involving a post-treatment step, which may reduce product yields. Preferably, the catalyst mixture is based on molybdenum, although the invention includes the use of tungsten or one component being molybdenum sulphide and the other tungsten sulphide. Preferred promoters for the promoted catalyst component are cobalt or nickel, especially nickel. The catalysts are preferably supported; suitable supports are mentioned above, and alumina and carbon are especially preferred. The tungsten or molybdenum may be present at loadings of from 1 to 30% by weight, calculated as the oxide, preferably 5 to 25% by weight, and the promoter is suitably present at loadings of 0.1 to 5%, preferably 0.5 to 4%, calculated as the oxide. The catalyst mixture may he used in conventional manner and at conventional temperatures, pressures and space velocities. Suitable temperatures are 350°C to 480°C; suitable hydrogen partial pressures are 50 to 250 bar. Suitable space velocities are 0.1 to 3.0⁻¹h. The hydrocracking stage may be carried out in a conventional reactor using a fixed catalyst bed or a moving catalyst bed, preferably such as an ebullating bed. The invention has particular advantages when used with a moving bed ie one in which partial catalyst replacement may be practised, in that the proportion of promoted to unpromoted catalyst may he varied during operation of the process in order to adjust the product mix. This may he a more effective adjustment method than varying the other process variables. Suitably, the promoted catalyst is present in an amount of from 5 to 20 vol% of the total catalyst. The unpromoted catalyst, unlike the promoted catalyst, is not readily available commercially. However, it may he prepared using known catalyst preparation methods, i.e. by impregnation of a support. It has heen found that the conventional step of calcining may he disadvantageous with regard to overall conversion, compared to air drying at up to 105°C, or vacuum drying. The catalysts may be pre-sulphided or sulphided in situ, e.g. in a first run or by virtue of the sulphur content of the extract/solvent feedstock. The first, liquefaction, stage of the process is not critical to the present invention and may he carried out in manner known per se. US-A-4 451 913 discloses a process for hydrocracking a supercritical gas extract of carbonaceous material to produce light distillate, including chemical feedstocks and transport fuels. This Prior art process utilises a catalyst comprising only a promoted catalyst and at supercritical conditions, in contradistinction to the present invention which is concerned with a two-stage coal liquefaction process employing a liquid solvent and a mixed catalyst. The invention may be further understood with reference to the accompanying Table 1, which gives analysis of feedstock and product for a single cycle hydrocracker test. Coal solutions were prepared by extraction of coal from Point of Ayr colliery, Wales, with a hydrogenated anthracene oil boiling in the range 250 to 450°C, at a 2 :1 solvent to coal ratio, temperature of 410⁰C and pressure of 15 bar g. In order to improve the accuracy of measurement of the change of concentration of components during hydrocracking, the coal solution was concentrated to about 50% extract by distillation. The concentrated solution was hydrocracked at 450°C and 25 bar hydrogen pressure over a variety of pre-sulphided catalysts in a fixed bed reactor. Analyses of the feedstock, total liquid product and the 300-450°C fraction of feed and product (representing the solvent after concentrating the feed solution) ar given in the attached Table 1. In the Table, particular note should he taken of the change in the saturates concentration of the solvent, and of the conversion of the extract. Other measures of the extent of hydrogenation are the changes in total hydrogen and aromatic hydrogen contents. The first five catalysts listed in the Table are commercially available but have heen given internal code numbers. LH27 is cobalt and molybdenum on alumina, and the other four are nickel and molybdenum on alumina. These five catalysts gave similar conversions, in the range of 63-70%, similar saturates formation of 5 - 7%, and similar increases in hydrogen and aromatic hydrogen contents of 2.0 - 2.2% and 1.3 - 1.5%, respectively. To test the reliability of our laboratory techniques of catalyst preparation, we simulated LH11 by depositing 3% NiO and 15% MoO3 on alumina, and calcining (code LH24). This catalyst gave results generally similar to those from the commercial catalysts. In catalyst preparation LH22, 28 and 23 (15% MoO3 on alumina, air dried at 105 C; 15% MoO3 on alumina, vacuum dried; 15% MoO3 on alumina, calcined; respectively), the nickel promoter was omitted, and a substantial reduction in the formation of saturates, to 1.6 - 2.9%, was observed, together with smaller reductions in the changes in hydrogen and aromatic hydrogen contents. The conversion was also reduced; this effect was more noticeable when the catalyst was calcined (LH23) then when it was merely dried before use (LH22 and 28). Using carbon as the support instead of alumina, (LH19: 15% MoO3 on active carbon, air dried at 105°C) gave similar results, except that less light distillate (C5-300°C) and more solvent (300-450° C) were formed, and nitrogen and sulphur were less effectively removed. In an attempt to improve the conversion achieved with the molybdenum catalysts without significant increase in the saturates formation, catalysts of intermediate composition between those with no promoter and the commercial catalysts were prepared. In LH25, the nickel promoter was introduced at one third of the loading (1%) of nickel in LH11l, but this produced results similar to those obtained with the full 3% nickel in LH24. In catalyst LH26, molybdenum catalyst LH22 was mixed in equal proportions with catalyst LH11, but the results were closer to those obtained with LH11 than those obtained with LH22. It was considered that the effects of mixing catalysts were likely to he non-linear, and a further catalyst was prepared by mixing 90 parts of catalyst LH22 with 10 parts of LH11. This mixed catalyst was tested in a laboratory coal extraction pilot plant permitting recycle of a solvent fraction from the hydrocracker, as described helow. Point of Ayr coal was extracted with a 250°C + recycle solvent, and the coal solution was hydrocracked at 425°C and 210 bar hydrogen pressure. The product from the hydrocracker was cut at 250°C to separate product and solvent, and excess unconverted material boiling above 450 C was removed. The quantity of this material in the recycle solvent was controlled at about 30%. Product yields and the composition of the 250-450°C solvent distillate were measured in each cycle. Three runs were carried out to compare the performance of different catalysts. In run A, the catalyst used was LH11 and the run comprised four cycles. In run B, the catalyst was 10% molybdenum on carbon. For the first three cycles the space velocity was the same as in run A, and in the next three cycles the space velocity was halved to increase conversion. In run C, the catalyst was the 90/10 mixed catalyst referred to above; the run comprised seven cycles at the half space velocity. The saturates content of the solvent distallate in each cycle of each run are plotted in the accompanying Figure. In run A, the saturates content increased to 28% in four cycles; in run B, the saturates content barely increased above 6% even at the lower space velocity. In run C, the content stabilises at an acceptable level of 18%. The beneficial effect of the unpromoted catalyst in runs B and C is clearly shown in the Figure. The conversion results are shown in the following Table 2. The molybdenum on carbon catalyst was less reactive than LH11 and gave lower conversions even at the half space velocity The mixed catalyst, however, exhibited an activity approaching that of LH11, and gave a good yield of distillate with decreased yield of residual material at the half space velocity. In all runs, the solvent retained a sufficiently high content of hydrogen donors, as shown by good extraction of the coal. We concluded from the results given that the mixed catalyst gave the required overall performance.

Claims: A two-stage coal liquifaction process, comprising a coal with a liquid hydrogen donor solvent at elevated temperature and pressure, catalytically hydrocracking at least a portion of the extract and at least a portion of the solvent and recycling as solvent a fraction of the hydrocracked product, characterised in that the hydrocracking catalyst is a mixture of a promoted tungsten or molybdenum sulphide catalyst and an unpromoted catalyst, the promoted catalyst being present in an amount of from 5 to 20% by vol of the total catalyst, the promoted catalyst having tungsten or molybdenum present at loadings of from 1 to 30% by weight, calculated as the oxide and the promoter heing present at loadings of 0.1 to 5%, calculated as the oxide. A process according to claim 1, characterised in that the unpromoted catalyst has not heen calcined. A process according to claim 1 or 2, characterised in that a moving catalyst bed is used. A process according to any one of the preceding claims, characterised in that the promoted and the unpromoted catalysts comprise molybdenum sulphide. A process according to claim 4, characterised in that the catalysts are supported on alumina. A coal extract hydrocracking catalyst comprising a promoted tungsten or molybdenum sulphide catalyst characterised in that said catalyst is in admixture with an unpromoted catalyst and in that the promoted catalyst is present in an amount from 5 to 20% by vol of the total catalyst, the promoted catalyst having tungsten or molybdenum present at loadings of from 1 to 30% by weight, calculated as the oxide and the promoter being present at loadings of 0.1 to 5%, calculated as the oxide. A mixed catalyst according to claim 6, characterised in that the unpromoted catalyst has not be calcined. A mixed catalyst according to claim 6 or 7, characterised in that the promoted and unpromoted catalysts comprise molybdenum sulphide. A mixed catalyst according to claim 8, characterised in that catalysts are supported on alumina. A mixed catalyst according to claim 9 or 10, characterised in that the promoter is nickel sulphide. A mixed catalyst precursor comprising an unpromoted molybdenum or tungsten catalyst and a promoted molybdenum or tungsten catalyst, capable of being sulphided to form a catalyst according to any one of claims 6 to 10.

Inventors: JONES, MICHAEL ANDREW
Applicants: COAL INDUSTRY (PATENTS) LIMITED
Application year: 1987
Main classification: C10G47
IPC codes: B01J27, C10G1, C10G47