Research & Development

Coal Conversion Cookbook

We have thoroughly documented for you the existence of very real technologies which could enable us to convert our abundant coal into much-needed liquid transportation fuels and raw materials for our chemical manufacturing industries.

We have verified our reports with published news stories and with technical articles presented in scientific journals.

Herein we send you a complete textbook on the subject.

We'll forego excerpting passages accessible through the enclosed links, and won't append following comments.

But, note: This text was published prior to WWII in Great Britain. It was authored by one of the German scientists who invented the coal-to-liquid fuel process which the Nazis, and their Japanese allies, employed, as we've thoroughly documented, to power a war machine that overran most of Europe and much of Asia, and battered England's United Kingdom to it's knees. If you have been following our posts, you will know that somewhat similar circumstances are now evolving, wherein Communist China, a nation really not all that friendly to us, is forging ahead with a massive coal-to-oil industrialization based on technology and technical assistance provided by the United States, and others. It seems they have been receiving much assistance and guidance from West Virginia University, as we've documented, who are helping the Chinese to commercialize what is known as "The West Virginia Process" for converting coal into liquid fuels.

As follows: 

The Conversion of Coal into Oils

by Dr. Franz Fischer

Authorized English Translation
Edited
with a Foreword and Notes
by
R. Lessing

London: Ernst Benn Limited
8 Bouverie Street, E.C.4
1925

 Table of Contents

Section 1
534kb		 Foreword i
Author's Preface ii
Contents v
List of Illustrations ix
List of Tables xi
Introduction 15
Section 2
608kb		 I. Extraction by Solvents 20
  (a) The Yield of Oil by Extraction 20
  (b) Identification of Chemical Compounds in the Extracts 20
II. Production and Working-Up of Primary Tar 22
  (a) Methods of Destructive Distillation of Fuels 22
  (b) Special Laboratory Methods for the Production of Primary Tar 24
  (c) Yields of Primary Tar From Coal and Peat 25
  (d) Proximate Composition of Primary Tars 27
  (e) The Temperatures Required for the Production of Primary Tar 28
Section 3
779kb		   (f) Differentiation Between Various Primary Tars and Other Tars 30
  (g) The Chemical Compounds Found in Primary Tar and in Primary Benzines 38
  (h) The Liquor From Low-Temperature Carbonization 43
  (i) Composition and Application of Low-Temperature Carbonization Gas 43
Section 4
865kb		   (k) The Low-Temperature Benzine 46
  (l) The Position of Primary Tar Between Coke-Oven Tar and Petroleum 49
  (m) Semi-Coke 50
  (n) The Heat Balance of Low-Temperature Carbonization 56
  (o) The Development of Commercial Primary Tar Production 58
    1. Distillation Apparatus with External Heating 59
        Vertical Retorts 60
Section 5
939kb		         Horizontal Retorts 64
        Tunnel Kilns 68
        Rotary Retorts 71
        Retorts with Inner Lining 76
    2. Internal Heating 76
        Superheated Steam as Heating Agent 76
        Hot Producer Gas as Heating Medium 78
        Hot Coke-oven Gas as Heating Medium 79
        Carbonisation by means of Flue Gasses 80
Section 6
1002kb		     3. Combined Apparatus 81
        Hot-Run Generators fitted with Carbonising Retorts 81
        Retorts Combined with Low-Temperature Producers 84
        Preliminary Carbonization of Furnace Fuel 87
  (p) The Influence of Retort Design Upon the Composition of Primary Tars and Gas Benzines 89
  (q) The Influence of Coal Drying on the Oil Recovery 91
  (r) Utilisation and Working-Up of Primary Tar 94
    1. Direct Utilisation of Primary Tar  94
    2. Working-Up of Primary Tar by Distillation 94
        Chemical Changes on Distillation 94
Section 7
544kb		         Working-up by Distillation at Ordinary Pressure 97
        Distillation at Ordinary Pressure and Chemical Treatment 99
        Working-up of Primary Tar by means of Superheated Steam and Chemical Treatment 100
        Working-up in a High Vacuum 104
    3. Separation and Utilisation of Phenols 106
        The Disadvantages of Phenols and their Corrosion of Metals 106
        The Utilisation of Phenols 108
        Methods of Separation of Phenols hitherto in Use 108
Section 8
292kb		         The Recovery of the Phenols by means of Superheated Water 110
Section 9
959kb		     4. The Reduction of Phenols of Primary Coal Tar to Benzol and Toluol 117
Section 10
605kb		     5. Benzine by Destructive Distillation of Primary Tar from Bituminous or Brown Coal 137
        Benzine by Cracking of Primary Tar at Ordinary Pressure 140
        Benzine by Cracking under Pressure 146
Section 11
705kb		         Benzine by the Burton Process 150
        Benzine by Cracking and Simultaneous Hydrogenation under High Pressure 151
    6. The Hydrogenation of Primary Tars, Tar Oils and Phenols 158
        With Catalysts 158
        Without Catalysts 159
    7. Summary of the Recovery of Light Motor Spirits From Primary Tars 160
    8. Purification of Primary Tar Oils by Oxidation Under Pressure 164
Section 12
414kb		     9. Formation of resins and Asphalt from Primary Tar by Oxidation under Pressure 166
    10. Fatty Acids from Crude Paraffin Wax by Oxidation under Pressure 166
  (s) Conversion of Low-Temperature Carbonisation Tar into Coke-oven Tar 166
  (t) Conversion of Brown Coal Tar into Aromatic Tar 169
  (u) Liquid Motor Fuels by Hydrogenation of Coal Tar, and Especially by Naphthalene 170
  (v) Importance of Primary Tar as Raw Material 173
Section 13
568kb		 II. Hydrogenation of Coal 174
  (a) By Means of Hydriodic Acid Under Pressure According to Berthelot 174
  (b) Comparative Hydrogenation of Different Coals with Hydriodic 177
  (c) Hydrogenation by Means of Sodium Formate 179
Section 14
626kb		   (d) Hydrogenation by Means of Carbon Monoxide and Water 187
  (e) Hydrogenation with Sodium Carbonate and Hydrogen 195
  (f) Destructive Distillation of Bituminous Coal at Higher Hydrogen Pressures 197
  (g) Hydrogenation of Coal According to Bergius at High Hydrogen Pressure 198
Section 15
569kb		 IV. Synthetic Processes 202
  (a) The Action of Electric Discharges 202
  (b) Catalytic Experiments at Ordinary Pressure 203
  (c) Liquid Hydrocarbons from Carbon Monoxide and Hydrogen Under Pressure 206
  (d) Alcohols and Formaldehyde from Carbon Monoxide and Hydrogen Under Pressure 210
  (e) Methyl Alcohol and Oils by Decomposition of Formates 211
Section 16
610kb		   (f) Synthol From Carbon Monoxide and Water Vapour Under Pressure 213
  (g) Catalytic Experiments in the Presence of Nitrogen 219
  (h) Catalytic Experiments with Carbon Dioxide and Hydrogen under Pressure 221
  (i) Synthol from Water Gas Under Pressure 221
    1. On the Need of a Metallic Hydrogen Carrier in the Contact Material 221
    2. Influence of the Form and Length by the Contact Material 223
    3. Influence of Bases and their Quantity upon the Oil Yield 224
Section 17
646kb		     4. Experiments with Hydrogen Carriers other than Iron 227
    5. Influence of the Composition of Water Gas 229
    6. Influence of Impurities in Water Gas 232
    7. Influence of Temperature, Pressure and Gas Velocity 232
    8. Determination of Yields in the Circulation Apparatus 234
  (k) Carbon Dioxide and Hydrogen in the Circulation Apparatus 240
  (l) Carbon Dioxide and Methane in the Circulation Apparatus 241
Section 18
641kb		   (m) Carbon Monoxide and Methane in the Circulation Apparatus 241
  (n) Examination of Products of Reaction 246
  (o) Road Tests of Synthol 248
  (p) Conversion of Synthol into Synthin 248
  (q) Formation of Petroleum from Water Gas 248
  (r) Attempt at an Explanation of the Synthol Process 250
Section 19
664kb		   (s) Industrial Applicability of the Synthol Process 255
V. Hydrocarbons from Carbides 258
  (a) Carbides which Directly Yield Liquid Hydrocarbons 258
  (b) Carbides Giving Hydrocarbons which can be Converted inot Liquids 261
Appendix (Editor's Notes) 263
  (a) Recent Developments in Low-Temperature Carbonisation 263
      Parker Plant 263
      Maclaurin 266
Section 20
825kb		   (b) Lessing Process for the Separation of Oils and Pitch from Tar 269
  (c) Hydrogenation of Coal in the Absence of Oil 271
Bibliography 274
Index 279

Coal and Plastics Conversion in Pittsburgh

 
 
We've told you about research in other places around the world into optimizing the process of converting our abundant coal into much-needed liquid fuels by combining coal with waste plastic as a raw material for the fuel-making process.
 
Such research has been conducted in the US, as well, and we present the enclosed report as evidence of that fact.
 
As in other reports we've submitted, it's important, we think, to note that these Pittsburgh, PA, researchers describe synergies realized by combining coal with waste plastics to synthesize liquid fuels.
 
The excerpt:
 
"Investigation of first stage liquefaction of coal with model plastic waste mixtures
 
Author(s): Rothenberger, K.S., et. al., Pittsburgh Energy Technology Center; 1995
 
As part of the U.S. Department of Energy (USDOE) Fossil Energy program, the Pittsburgh Energy Technology Center (PETC) recently initiated research in coal-waste coprocessing. Coal-waste coprocessing is conversion to liquid feedstocks of a combination of any or all of the following: coal, rubber, plastics, heavy oil, and waste oil. The current effort is on the combined processing of coal, waste oil, and plastics. One reason commonly cited for coprocessing of coal and plastic materials is the higher hydrogen-to-carbon ratio in most plastics as compared to coal, which is hydrogen deficient relative to the petroleum-like liquids desired as products. Furthermore, the free radicals which are present in coal and believed to be produced in the early stages of coal dissolution could aid in the breakdown of plastic polymers. In this study, screening tests have been conducted in microautoclave reactors, 1-L semi-batch stirred autoclave reactors, and a small-scale continuous unit. All tests employed Black Thunder subbituminous coal with plastic waste streams containing polyethylene (PE), polystyrene (PS), and polyethylene terephthalate (PET) in various combinations and proportions. The materials and conditions were chosen to be compatible with those being investigated by other participants in the USDOE Fossil Energy program, including the proof-of-concept (POC) scale plant at Hydrocarbon Research, Inc. (HRI) in Princeton, NJ. Due to the rapidly evolving nature of the coal-waste coprocessing initiative, many of the experiments reported here were designed to identify potential problem areas for scheduled runs on larger units rather than to systematically map out the chemistry involved with coliquefaction of coal and plastic materials. However, insights into both chemistry and operability of coal-waste coprocessing can be gained from the data."
 
We had earlier reported to you the existence of the HRI "proof-of-concept" plant in New Jersey, and remain alert for published results of the work performed there. However, like much else about coal-to-liquid research, and actual commercial operations, that are documented to have been undertaken in the United States, published results, for whatever reason, are difficult to find. We'll try to remain positive and refrain from offering distractive speculation as to why that might be. You can draw your own conclusions.
 
But, as in the other, international, research we've reported, this Pittsburgh study confirms: Coal and waste plastics can be converted together into liquid fuels, thus utilizing our most abundant natural resource to manufacture something we desperately need while consuming some persistent environmental pollutants at the same time.
 

Coal & Muni Waste to Liquids - Auburn

 
An economic study for the co-generation of liquid fuel and hydrogen from coal and municipal solid waste
 

We've previously reported on the coal-to-liquid development efforts underway at Auburn University, a member, with WVU and other schools, of the Consortium for Fossil Fuel Science. They, too, are examining the potential for enhancing the conversion of coal into liquid fuels, and the generation of Hydrogen, by combining coal with other available materials, including various wastes.
 
The technical details seem well-established. We can convert coal, and some wastes, especially cellulose  and certain plastics, into components from which we can synthesize liquid fuels compatible with our current transportation fleet and infrastructure. That has been, without question, proven.
 
Now, it seems, one focus of research is on the economics of performing those conversions. 
 
The excerpt:  
 
"Anthony Warren and Mahmoud El-Halwagi

Chemical Engineering Department, Auburn University, Auburn, AL 36849, USA

Abstract

The objective of this paper is to assess the technical and economic feasibility of a new process for co-liquefying coal and plastic wastes. This assessment is based on incorporating recent experimental data on plastic/coal liquefaction within a conceptual process framework. A preliminary design was developed for two process configurations. The primary difference between the configurations is the source of hydrogen (coal versus cellulosic waste). The assessment was based on co-liquefying 720 tons per day of plastic waste with an equivalent amount of coal on a weight basis. The plant products include hydrocarbon gases, naphtha, jet fuel and diesel fuel. Material and energy balances along with plant-wide simulation were conducted for the process. Furthermore, the data on plastic-waste availability, disposal and economics have been compiled. The results from the economic analysis identify profitability criteria for gross profit and thus return on investment based on variable conversion, yield and tipping fee for plastic waste processed."

These Auburn researchers appear to have addressed some narrow concerns, and no real conclusions are presented. But, the fact that such specific economic assessments have been, and are being, performed attests to the practical reality of coal, and waste, conversion to liquid fuels, just as much as does the research and development being conducted on a broad scale into the technical details of the process.

Japan to Recycle CO2

The amount of CO2 Mitsui Chemicals intend recycling, as related in the two reports enclosed, into valuable plastics manufacturing raw materials seems small, even miniscule when compared to the overall volume of CO2 emissions. But, the technology is real, as we've documented from other sources.
 
We can reclaim the Carbon Dioxide co-product of our coal-use industries and convert it into useful plastics, and even more liquid fuel.
 
As follows:
 
 
 
Mitsui Chemical Inc. of Japan has decided to begin construction of a pilot plant for continued development of producing methanol from industrial CO2 effluent and photocatalyst produced hydrogen. Due to build starting in October of 2008 with completion next February the plant is expected to go into use in March of 2010, the plant’s annual yield would work out to be the U.S. equivalent of over 33,000 gallons.
 
 
 
Mitsui Chemicals Inc. ("MCI") has decided to begin construction of a pilot facility which will be used to continue the company's efforts to develop a methanol synthetic process from CO2. MCI has been pushing forward the development of "Chemical immobilization of CO2", which synthesizes methanol later used in the production of olefins and aromatics, using the CO2 emitted from factories and hydrogen obtained from water photolysis."
 
Interestingly, the Japanese seem to propose obtaining the needed Hydrogen from, as we've earlier documented to be possible, water, by using solar energy, i.e., "photolysis". We know that Hydrogen can be obtained from water via electrolysis, but that requires electricity, which could be generated from renewable sources, such as hydroelectric, but might require the use of more coal for power generation. If sunlight can be captured effectively enough to accomplish the task, that would be yet another process efficiency wherein environmental energy can be harnessed to help clean up the environment.
 
Coal use doesn't generate pollutants, just valuable co-products that can be profitably reclaimed and employed by industry.

CoalTL Technology Converts Wate Plastic

 
Although coal isn't the focus of this release about the University of Kentucky's work in converting waste plastic into liquid fuels, coal-to-liquid conversion technology is at the heart of the research this article describes. And, it is noted in the report that waste plastics can be liquefied with coal..
 
Explanatory note follows the excerpt:

"Waste plastic yields high-quality fuel oil.

Ironically, after all the trouble of reclaiming plastic waste from gooey trash, recycled products often cost more and look worse than virgin plastics -- a situation that displeases consumers.

But fuel chemists M. Mehdi Taghiei and his colleagues at the University of Kentucky in Lexington report a new, efficient way of converting plastic waste into high-quality, saturated fuel oil.

"It's good oil, too--much like imported crude oil," Taghiei said this week in Chicago at a meeting of the American Chemical Society. "This oil is even lighter and easier to refine into high-octane fuel than imported oil. It has no sulfur and fewer impurities." Similarly, the chemists found they could liquefy plastic with coal, also producing high-quality fuel.

The researchers mixed various types of plastic with zeolite catalysts, including HZSM-5 and tetralin

Furthermore, oil yields proved high: Milk jugs generated 86 percent oil, soda bottles, 93 percent. Polyethylene, another common soft plastic, eked out 88 percent. When liquefied with coal in a roughly half-and-half mixture, the plastics turned into even better oil.

"In terms of the economics of this process, we have done some estimates," says Kentucky chemist Gerald P. Huffman, a coauthor of the report. "To convert coal and plastic simultaneously into oil right now costs about $27 or $28 per barrel, compared with $18 to $20 per barrel for imported oil. But we're quite confident that we can drive the cost of converted oil down to roughly the cost of imported oil. This process may be commercially viable within five to 10 years."

The reporter, we believe, seems to inadvertently and erroneously identify "tetralin", above, as a zeolite catalyst. It is not. It is, however, as we understand it, a Hydrogen-donor solvent employed by West Virginia University in their "West Virginia Process" for converting coal into liquid fuels and chemicals. The "HZSM-5" is, though, a zeolite, and likely to be the same one used by Exxon-Mobil in their "MTG" (r) process for converting methanol, derived from coal and other sources, into gasoline.

In any case, this research confirms that coal and some types of waste plastic can be converted together into liquid fuels. Coal can lead us to domestic liquid fuel self-sufficiency, and help us to clean up the environment, by enabling the profitable recycling of waste plastic, while it does so.

 

  1. Coal & PlasticTL - Utah
  2. Coal & Waste Plastic TL - Pakistan
  3. More Pakistan Coal Liquefaction
  4. Pakistan Can Use Coal as Gas Substitute

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