Direct Primary Coal Liquefaction via an Innovative Co-processing Approach with Waste and Petroleum Feedstocks

ended

The main goal of the proposed research is to improve the viability and environmental performance of direct coal liquefaction (DCL) by providing a framework where it can develop in the EU without the need for extremely large-scale plant and with a focus on low-rank and perhydrous coals that provide the highest conversions at lowest cost. The research will establish a distributed approach to DCL that will enable it to be introduced as a technology suitable for co-processing a variety of wastes, including plastics, tyres and bio-wastes which can thermally decompose into effective solvents. The two primary conversion routes will be investigated to optimise the use of wastes and co-feeds are (i) the use solvents with some H-donor properties without hydrogen pressure and (ii) the use of waste and non-donor solvents with added hydrogen pressure with means for in-situ generation being investigated. The primary liquefaction products will then be assessed for co-processing with petroleum feedstocks in existing refinery facilities with a test programme involving both catalytic cracking and hydrocracking with hydro-isomerisation of the naphtha produced from both processes. The research will identify and implement the improvements that need to be made to existing catalysts to optimally co-processing heavy coal liquids and petroleum fractions. This flexible approach will enable plants to operate on relatively small scales (ca. < 200 tonne p.d.) to provide intermediate heavy oil products suitable for further processing in existing oil refinery operations, as well as minimising CO2 emissions from co-processing a range of bio-wastes. The results of the research programme will provide the basis for designing two specific DCL modules as the basis for pilot-scale operation, based on the use of solvents with hydrogen-donor capabilities and non-donor solvents with added hydrogen pressure.