Energy & Fuels, Vol.19, No.2, 489-498, 2005
Analyses of Illinois no. 6 coal liquefaction results generated in the Wilsonville, Alabama unit
A database was set up to correlate the coal liquefaction results generated at the Department of Energy (DOE) Advanced Two-Stage Coal Liquefaction Facility in Wilsonville, AL. Published information available in the public domain was used, centering on runs made with Illinois No. 6 seam bituminous coal with two reactors in a close-coupled mode. A linear regression analysis was performed to determine the effects of process variables on conversions and product yields. Bimodal catalysts were more effective than a unimodal catalyst, as indicated by 10 wt % higher resid + unconverted coal conversion, 1 wt % greater hydrogen consumption, 19 wt % greater C-4-1000 degrees F liquid production, and 14 wt % lower resid yield. Another significant result was a lower coal conversion, hydrogen consumption, C-1-C-3 yield, light (IBP-350 degrees F) distillate yield, and C-1-C-3 selectivity, when using half-volume reactors rather than full-volume reactors under similar conditions, including space velocities. This was apparently due to flatter reactor temperature profiles and lower catalyst-to-thermal volume ratios. Overall preferred processing conditions for converting coal to distillate liquids included the use of EYP-AO-60 catalyst, high reactor temperatures (> 810 degrees F, 432 degrees C) and a high process solvent resid concentration (> 50 wt %, if mechanically possible). The space rate of coal in the reactors is best set at a point where resid production is minimized, if justifiable by process economics.