Patent ID: 8226821

Claim:
An integrated multi-stage liquefaction and hydrotreatment process for directly converting coal into lower molecular weight liquid hydrocarbons which comprises feeding coal and recycled slurry under liquefaction conditions in a plurality of liquefaction reactors to produce a coal liquid effluent, and subsequently hydrotreating said coal liquid effluent in a hydrotreatment reactor wherein: 1) said liquefaction reactors and said hydrotreatment reactor are arranged in series with a separator unit in between said liquefaction reactors and said hydrotreatment reactor to separate said coal liquid effluent into a vapor fraction boiling below 1000° F. and a residue fraction containing the heavier components including ash and unconverted coal and wherein only said vapor fraction is thereafter fed to said hydrotreatment reactor; 2) fresh catalyst is first added to said hydrotreatment reactor and is thereafter removed and cascaded to the first liquefaction reactor; and 3) a portion of said catalyst from the first liquefaction reactor is thereafter cascaded and utilized in the next liquefaction reactor in the series; and wherein the temperature of said hydrotreatment reactor is lower than the operating temperature of said first liquefaction reactor and the temerature of said first liquefaction reactor is lower than the next liquefaction reactor in the series.