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1. WO1979001062 - COMBINED COAL LIQUEFACTION AND GASIFICATION PROCESS

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[ EN ]

I claim:
1. A combination bituminous coal liquefaction-gasification process comprising passing mineral-containing bituminou feed coal, hydrogen, recycle dissolved liquid solvent, recycle normally solid dissolved coal and recycle mineral residue to a coal liquefaction zone to dissolve hydrocarbonaceous material fro mineral residue and to hydrocrack said hydrocarbonaceous material to produce a mixture comprising hydrocarbon gases, dissolved liquid, normally solid dissolved coal and suspended mineral residue; recycling to said liquefaction zone a portion of said dissolved liquid, normally solid dissolved coal and mineral resi separating distillate liquid and hydrocarbon gases from said-normally solid dissolved coal and mineral residue to produce a gasifier feed slurry comprising substantially the entire 850°F.+ normally solid dissolved coal and mineral residue yield of said liquefaction zone; passing said gasifier feed slurry to a gasification zone; said gasification zone including an oxidation zone for the conversion of the hydrocarbonaceous material therein to synthesis gas; converting a portion of said synthesis gas in a shift reaction to a gaseous hydrogen-rich stream and passing said hydrogen-rich stream to said liquefaction zone to satisfy the process hydrogen requirement thereof; the amount of 850°F.+ normally solid dissolved coal in said gasifier feed slurry being in excess of the amount of normally solid dissolved coal
necessary to satisfy the process hydrogen requirement of said liquefaction zone; the amount of 850βF.+ normally solid dissolved coal in said gasifier slurry in excess of the amount necessary to satisfy the process hydrogen requirement increases the thermal efficiency of said process by producing an excess amount of synthesis gas and is in the range defined by the formula:

0M R -= 13 + (8-0) - 3(Fe - 1.5)
where
Fe = iron content of feed coal in weight percent
O = oxygen content of feed coal in weight percent
= range of the yields of 850---F.+ dissolved coal
in excess of the yield of 850°F.+ dissolved
coal necessary to satisfy the process
hydrogen requirement, where the yields are
expressed in weight percent of dry feed coal;
the combustion heating value of said excess amount of
synthesis gas being at least 5 percent of the total energy requirement of said process; and burning said excess amount of synthesis gas as fuel within said process.
2. The process of claim 1 wherein said separation of distillate liquid and hydrocarbon gases from normally solid dissolved coal and mineral residue is performed in a vacuum distillation zone so that said separation is substantially complete.
3. The process of claim 1 wherein said gasifier feed slurry comprises substantially the entire hydrocarbonaceous feed to said gasification zone.
4. The process of claim 1 including the removal of mineral residue as slag from said gasifier zone.
5. The process of claim 1 wherein there is no step for the separation of mineral residue from normally solid dissolved coal.
6. The process of claim 1 wherein the maximum temperature in said gasification zone is between 2,200 and 3,600°F.
7. The process of claim 1 wherein the maximum temperature in said gasification zone is between 2,500 and 3,600°F.
8. The process of claim 1 wherein the total coke yield in said liquefaction zone is less than 1 weight percent, based on feed coal.

9. The process of claim herein some synthesis gas is converted to another fuel.
10. A combination coal liquefaction-gasification process comprising passing a mineral-containing feed coal selected from the group comprising subbituminous coals and lignites, recycle dissolved liquid solvent, recycle normally solid dissolved coal and recycle mineral residue to a coal liquefaction zone to dissolve hydrocarbonaceous material from mineral residue and to hydrocrack said hydrocarbonaceous material to produce a mixture comprising hydrocarbon gases, dissolved liquid, and normally solid dissolved coal and suspended mineral residue; recycling to said liquefaction zone a portion of said dissolved liquid, normally solid dissolved coal and mineral residue; separating distillate liquid and hydrocarbon gases from said normally solid dissolved coal and mineral residue to produce a gasifier feed slurry; said gasifier feed slurry comprising substantially the entire 850°F.+ normally solid dissolved coal and mineral residue yield of said liquefaction zone; passing said gasifier feed slurry to a gasification zone; said gasification zone including an oxidation zone for the conversion of the hydrocarbonaceous material therein to synthesis gas; converting a portion of said synthesis gas in a shift reaction to a gaseous hydrogen-rich stream and passing said hydrogen-rich stream to said liquefaction zone to satisfy the process hydrogen requirement thereof; the amount of 850°F.+ normally solid dissolved coal in said gasifier feed slurry being in excess of the amount of normally* solid dissolved coal necessary to satisfy the process hydrogen requireme of said liquefaction zone; the amount of 850°F.+ normally solid dissolved coal in said gasifier slurry in excess of the amount necessary to satisfy the process hydrogen requirement increasing the thermal efficiency of said process by producing an excess amount of synthesis gas and is in the range defined by the formula
y R = 13 + ( 18-0) - 3 (Fe - 0.5)
where
Fe - iron content of feed coal in weight percent
O = oxygen content of feed coal in weight percent
R =- range of the yields of 850°F.+ dissolved coal
in excess of the yield of 850°F.+ dissolved
coal necessary to satisfy the process
hydrogen requirement, where the yields are
expressed in weight percent of dry feed coal;
the combustion heating value of said excess amount of synthesis gas being at least 5 percent of the total energy requirement of said process; and burning said excess amount of synthesis gas as fuel within said process.
11. The process of claim 10 wherein said separation of distillate liquid and hydrocarbon gases from normally solid dissolved coal and mineral residue is performed in a vacuum distillation zone so that said separation is substantially
complete.
12. The process of claim 10 wherein said gasifier feed slurry comprises substantially the entire hydrocarbonaceous feed to said gasification zone.
13. The process of claim 10 including the removal of mineral residue as slag from said gasifier zone.
14. The process of claim 10 wherein there is no step for the separation of mineral residue from normally solid
dissolved coal.
15. The process of claim 10 wherein the maximum temperature in said gasification zone is between 2,200 and 3,600°F.
16. The process of claim 10 wherein the maximum temperature in said gasification zone is between 2,500 and 3,600°F.
17. The process of claim 10 wherein the total coke yield in said liquefaction zone is less than 1 weight percent, based on feed coal.
18. The process of claim 10 wherein some synthesis gas is converted to another fuel.