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NEW IRON CATALYSTS FOR THE DIRECT LIQUEFACTION OF COAL.

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THE AIM OF PROJECT IS TO DEVELOP AEROSOL TYPE IRON BASED CATALYSTS FOR APPLICATION IN THE DISPERSED MODE IN L-STAGE DIRECT LIQUEFACTION OF COAL.
An induction heated reactor has been designed and constructed for the direct liquefaction of coal. During the first experiments, the coupling of the inductive coil and the reactor was optimised in order to obtain a high heating rate (70 degrees Celsius per minute) and accurate temperature regulation (+/- 0.5 C).
Multistage liquefaction experiments have been performed with this reactor and have given better coal conversion to oils than a single stage low heating rate operation in the presence of an iron catalyst. These better results are explained, firstly, by a different deactivation of the iron sulphide catalyst because of the thermal treatment and, secondly, by insoluble product formation caused by radical polymerisation reactions.
In this 3-stage temperature procedure, the presence of catalyst and/or hydrogen donor solvent and/or a prehydrogenation step (at 400 C) are necessary to produce the high level of coal conversion to soluble products.
AN IMPROVED CATALYST COULD MATERIALLY IMPROVE THE ECONOMICS OF DIRECT LIQUEFACTION BY DECREASING THE SEVERITY OF PROCESS CONDITIONS AND/OR IMPROVING THE YIELD OF THE DESIRED LIQUID PRODUCTS.

THE CATALYSTS TO BE RESEARCHED IN THIS PROJECT WILL TAKE THE FORM OF VERY FINE AEROSOLS OF IRON OXIDE (FE2O3) POSSIBLY DOPED WITH SN OR MO.THE CATALYSTS WILL BE PREPARED IN A FLAME REACTOR.THEY WILL BE TESTED UNDER LIQUEFACTION CONDITIONS IN A BATCH REACTOR USING TETRALIN OR METHYLNAPHTALENE AS SOLVENT.SIMILAR TEST WILL BE CARRIED OUT USING CONVENTIONAL CATALYSTS,I.E. RED MUD AND NIMO/AL2O3 TO ESTABLISH A PERFORMANCE STANDARD AGAINST WHICH THE NEW CATALYSTS WILL BE MEASURED.CATALYSTS WILL BE CHARACTERISED AND THE RESULTING COAL LIQUIDS MEASURED AND ANALYSED IN AN ESTIMATED TOTAL OF 30 LIQUEFACTION TESTS.

ONCE A PROMISING CATALYST FORMULATION HAS BE IDENTIFIED A LARGE SAMPLE (1.5KG.)WILL BE PREPARED FOR PROVING TRIALS IN A CONTINOUSLY OPERATED LIQUEFACTION PILOT PLANT.

STATE OF ADVANCEMENT:
THE FIRST PROGRESS REPORT IS EXPECTED IN APRIL 1988.

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CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE
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