WO2014165415A2 - Procédés et dispositifs pour produire des composés aromatiques à partir de houille - Google Patents

Procédés et dispositifs pour produire des composés aromatiques à partir de houille Download PDF

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Publication number
WO2014165415A2
WO2014165415A2 PCT/US2014/032291 US2014032291W WO2014165415A2 WO 2014165415 A2 WO2014165415 A2 WO 2014165415A2 US 2014032291 W US2014032291 W US 2014032291W WO 2014165415 A2 WO2014165415 A2 WO 2014165415A2
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stream
coal
aromatics
dcl
product
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WO2014165415A3 (fr
Inventor
Richard F. Bauman
Kenneth Lee TRACHTE
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Accelergy Corp
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Accelergy Corp
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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G35/00Reforming naphtha
    • C10G35/04Catalytic reforming
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/02Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal by distillation
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/58Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins
    • C10G45/68Aromatisation of hydrocarbon oil fractions
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G47/00Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10Feedstock materials
    • C10G2300/1096Aromatics or polyaromatics

Definitions

  • the present invention relates to direct coal liquefaction processes for efficiently producing high-value aromatics from coal.
  • the pyrolysis method is of economic interest only as a byproduct of another process, e.g., producing coke from coal.
  • the methanol to aromatics (MTA) process would involve the gasification of the coal feed, typically by partial oxidation (POX), to produce syngas as the feed for methanol synthesis, converts coal to methanol and then converts methanol to aromatics by processing over a fixed or fluid bed of catalyst.
  • POX partial oxidation
  • a highly efficient and lower cost method and system for producing high-value aromatics from coal in which the feed coal is converted by direct coal liquefaction (DCL) to a 1000°F-, preferably an 800°F-, more preferably a 600 -750°F- product, most preferably a 600-700°F- product, at least the 350°F+ portion of which is then hydrocracked to produce a 350° F- product stream.
  • the DCL and hydrocracked 350°F- product streams are then hydroprocessed to remove sulfur, nitrogen and oxygen compounds and fractionated into approximately 160°F- and 160°F+ output streams.
  • the approximately 160/350°F output stream is ideal for aromatics production.
  • the product from the catalytic reformer can be processed in a solvent extraction unit to produce a pure aromatics product and a paraffinic raffinate.
  • the entire product can be passed over a bed of cracking catalyst in the same unit.
  • This bed isomerizes lower value ethyl benzene to more valuable para-xylene and benzene, and cracks the remaining paraffins into an approximately 160°F- product that can be separated from the aromatics in the distillation tower, thereby producing a higher value aromatic product and eliminating the need for solvent extraction.
  • the preferred DCL system includes a slurry DCL reactor containing a molybdenum or iron, preferably molybdenum, microcatalyst and is operated at high conversion with the product boiling above the 600-700°F range preferably being recycled and mixed with the DCL feed coal as a non-donor stream in a ratio of non-donor stream to coal at the input to the reactor (on a moisture free weight basis) of between 1.6 and 3.5:1.
  • non-donor is meant that the recycle stream has not been processed in a hydrotreater to partially hydrogenate multi-ring aromatic compounds in the stream in order to produce compounds that can donate hydrogen during liquefaction.
  • the bottoms from the DCL reactor can be gasified in a POX reactor.
  • the additional hydrogen may be provided by processing 160°F- product of the upgrading and the catalytic reformer by liquid POX or steam naphtha reforming (SNR). If natural gas is available, it can be used as the feed to the liquid POX or SNR instead of the 160°F- product.
  • FIG. 1 is a diagram of the flow stream of an embodiment of the method and apparatus of the invention in which the additional hydrogen is provided by POX.
  • FIG. 2 is a schematic diagram of a preferred direct coal liquefaction system suitable for use in the illustrated embodiments of the invention.
  • FIG. 3 is a diagram of the flow stream of an embodiment of the method and apparatus of the invention in which the additional hydrogen is produced from the 160°F- product stream.
  • FIG. 4 is a diagram of the flow stream of an embodiment of the method and apparatus of the invention in which the additional hydrogen is produced from natural gas feed.
  • FIG. 1 of the drawings there is illustrated a schematic of the overall flow scheme of a first embodiment of a coal to aromatics plant 100 according to the invention.
  • the coal feed 101 is supplied to the DCL unit 103 that is preferably operated at a high conversion of 80+% on a moisture and ash free (MAF) basis.
  • the DCL unit 103 coal is hydrogenated to produce an approximately a 1000°F-, preferably an 800°F-, more preferably a 600 -750°F- product, most preferably a 600-700°F- product stream 105 and an effluent stream 107 that consists of ash, unconverted coal, and liquids boiling above 1000°F.
  • the product stream 105 flows to the upgrader 109, in which at least the 350°F+ portion of the stream is hydrocracked to produce a 350° F- product stream.
  • This stream is then fractionated in the atmospheric fractionator 115 into approximatelyl60°F- and 160°F+ outputs 117 and 119, respectively.
  • Light gases produced in the DCL unit 103 and the upgrader 109 may be used to supply a portion of the fuel for the plant. Excess light gases (C2-) may be sent to a steam methane reformer to supply a portion of the hydrogen required by the DCL unit 103.
  • the bottoms stream 107 from the DCL unit 103 is gasified in the POX unit 111 for supplying additional hydrogen to the DCL unit 103 and the upgrader 109.
  • the approximately 160/350°F stream 119 from the fractionator 115 is typically made up of 85% to 90% naphthenes, 5 to 10% paraffins, and some single ring aromatics.
  • This stream is fed to the catalytic reformer 121 where the naphthenes are converted into aromatics.
  • the output of the catalytic reformer 121 is fed to the solvent extractor unit 123 where it is separated into a pure aromatics stream 125 and a lower boiling point paraffinic raffinate stream 127.
  • the aromatics stream 125 can be separated into its benzene, toluene and xylene components by distillation.
  • This bed converts the lower value ethyl benzene to more valuable para-xylene and benzene, and cracks the remaining paraffins into a 160°F- product that can be separated from the aromatics by distillation, thereby producing a higher value aromatic product and
  • the C0 2 produced by the POX unit 111, and optionally, by the DCL reactor system 103 and/or other components of the liquefaction and upgrading system, is fed to the algae production system 129, which includes a photo-bio reactor (PBR) in which the C0 2 is used to produce preferably blue-green algae through photosynthesis.
  • the DCL reactor system 103 and especially the upgrading system 109 also produce N H 3 , which ca n be fed to the algae production system 129 as a nutrient.
  • production system 129 is preferably used to produce a biofertilizer 131.
  • Methods and a ppa ratus suita ble for use i n the present i nvention for prod uci ng a lgae a nd
  • bioferti lizer a re disclosed i n U .S. Patent Application No. 13/316,546 that was fi led on Dece m ber 11, 2011, the disclosure of which is he reby I ncorporated by reference i n its entirety.
  • the coal feed is dried and crushed in a conventional gas swept roller mill 201 to a moisture content of 1 to 4 %.
  • Crushed and dried coal is fed into a mixing tank 203 where it is mixed with a stream constituted by a 600 to 700°F+ fraction, preferably a 650°F+ fraction, of the output of the liquefaction reactor to form a slurry stream.
  • embodiment preferably is in the form of an aqueous water solution of phosphomolybdic acid (PMA) in an amount that is equivalent to adding between 50wppm and 2% molybdenum relative to the dry coal feed.
  • PMA phosphomolybdic acid
  • typical operating temperature ranges from 300 to 600°F and more preferably between 300 and 500°F.
  • the catalyst containing slurry is delivered to the slurry pump 205. The selection of the appropriate mixing and temperature conditions is based on experimental work quantifying the rheological properties of the specific slurry blend being processed.
  • the coal in the slurry leaving the mixing tank 203 has about 0.1 to 1.0% moisture.
  • the slurry formed by the coal, 600 to 700 to 1,000°F stream from the vacuum fractionator 221, and the 600 to 700°F+ stream fraction from the atmospheric fractionator 219 is pumped from the mixing tank 203 and the pressure is raised to about 2,000 to 3,000 psig (138 to 206 kg/cm 2 g) by the slurry pumping system 205.
  • the resulting high pressure slurry may be preheated in a heat exchanger (not shown), mixed with a treat gas consisting of recycled and makeup treat gas containing over 80% hydrogen, and then further heated in furnace 207.
  • the coal slurry and hydrogen mixture is fed to the input of the first stage of the series- connected liquefaction reactors 209, 211 and 213 at between 600 to 700°F (316 to 371°C) and 2,000 to 3,000 psig (138 to 206 kg/cm 2 g).
  • the reactors 209, 211 and 213 are simple up-flow tubular vessels, the total length of the three reactors being 40 to 200 feet. The temperature rises from one reactor stage to the next as a result of the highly exothermic coal liquefaction reactions.
  • a portion of the hydrogen based treat gas is preferably injected between reactor stages.
  • the hydrogen partial pressure in each stage is preferably maintained at a minimum of about 1,000 to 2,000 psig (69 to 138 kg/cm 2 g).
  • the effluent from the last stage of liquefaction reactor is separated into a gas stream and a liquid/solid stream, and the liquid/solid stream let down in pressure, in the separation and cooling system 215.
  • the gas stream is cooled to condense out the liquid vapors of H20, naphtha, distillate, and solvent.
  • the remaining gas is then processed to remove H 2 S, NH 3 and C0 2
  • the depressurized liquid/solid stream and the hydrocarbons condensed during the gas cooling are sent to the atmospheric fractionator 219 where they are separated into light ends and in the preferred embodiment, a 600 to 700°F- fraction, and a 600 to 700°F+ fraction.
  • the light ends are processed to recover hydrogen and Ci-C 2 hydrocarbons that can be used for fuel gas and other purposes.
  • the 600 to 700°F- fraction is sent to upgrading for aromatics production.
  • the fractionator 219 could be arranged to produce 1000°F- and 1000°F+ fractions or 800°F- and 800°F+ fractions in which the 1000°F- or 800°F- fraction would be sent to the upgrading step.
  • a portion of the 600 to 700°F+ (316 to 371°C+) is recycled to the slurry mix tank.
  • the remaining 600 to 700° F+ fraction produced from the atmospheric fractionator 219 is fed to the vacuum fractionator 221 wherein it is separated into a 1000°F- fraction and a 1000°F+ fraction.
  • the 1000°F- fraction is added to the 600 to 700°F+ stream being recycled to the slurry mix tank 203.
  • the 1000° F+ fraction from the vacuum fractionator 221 is sent to be gasified by the POX system 223 (shown in FIG. 1 as POX 111) to generate hydrogen for use in the liquefaction and upgrading.
  • the 1000° F+ bottoms from the vacuum fractionator 221 may be processed in a Circulating Fluid Bed boiler, a cement plant, or sold as a feed for asphalt paving or electrode manufacture.
  • G.E., Shell, and others offer commercial processes for gasification (partial oxidation) of the 1000°F+ bottoms and Circulating Fluid Bed boiler manufactures such as Foster- Wheeler and Alstom offer technology for combusting the 1000°F+ bottoms.
  • Catalysts useful in DCL processes also include those disclosed in U.S. Patents Nos. 4,077,867, 4,196,072 and 4,561,964, the disclosures of which are hereby incorporated by reference in their entirety.
  • Other DCL reactor systems suitable for use in the process of the invention are disclosed in U.S. Patents Nos. 4,485,008, 4,637,870, 5,200,063, 5,338,441, and 5,389,230, and U.S. Patent Application No. 13/657,087,the disclosures of which are hereby incorporated by reference in their entirety.
  • the preferred DCL Process combines several elements that contribute to maximum BTX Product production and maximum thermal efficiency. These include, very importantly, the recycle of a non-donor 600 to 700°F+ stream, preferably including atmospheric fractionator bottoms, to maintain a ratio of the recycle stream to coal at the input to the reactors 209, 211, 213 that is between 1.6:1 and 3.5:1 on a moisture free weight basis; the use of a microcatalyst in the form of finely divided molybdenum; and the use of a much lower treat gas rate than in previous systems. Also, the use of bottoms recycle, and multiple slurry reactors in series contribute to the benefits of the process.
  • microcatalyst which is either a compound of molybdenum or iron, more preferably molybdenum, and added at 100 to 1,000 wppm, more preferably 100 to 500 wppm, and most preferably 100 to 300 wppm, eliminates several disadvantages to the use of a donor solvent such as required by prior DCL systems.
  • energy is lost during preparation of the donor solvent.
  • energy is required to preheat the donor solvent in the solvent hydrotreater and hydrogen must be compressed and circulated around the hydrotreater.
  • the heat release during partial hydrogenation of the donor solvent is lost during cooling prior to separation of hydrogen for recycle.
  • the 600 to 700° F+ fraction recycled from the atmospheric fractionator 219 and the 1000° F - fraction from the vacuum fractionator 221 as the non-donor stream being recycled to the slurry mix tank 203 provides preheat for the coal and solvent in the slurry mix tank 203. This raises the temperature in the mix tank to 300°F to 500°F, more preferably 350°F to 500°F, and most preferably about 400 to 500°F. This further reduces the energy requirement for preheating the slurry prior to liquefaction.
  • a significant portion of the of the microcatalyst is entrained in the 600 to 700° F+ fraction recycled from the atmospheric tower 219, so that recycling a larger portion of such fraction increases the catalyst concentration in the DCL reactors 209, 211, 213, thereby decreasing the requirement for the addition of fresh catalyst precursor and increasing the conversion efficiency of the DCL process.
  • Use of the non-donor 600°F to 700°F+ stream, more preferably 630°F to 670°F+, and most preferably a 650°F+, process derived recycle solvent in the DCL process reduces cracking, relative to donor solvent, and produces a 650°F- product with a greater fraction of diesel and less light gases and naphtha.
  • the 650°F- product can be selectively upgraded to finished products in fixed bed upgrading reactors.
  • the much lower treat gas rate of 600 to 900 NL per kg of slurry has a significant impact on thermal efficiency, plant investment, and operating cost.
  • the required recycle treat gas rate for the DCL process of the invention is up to three times lower than the preferred gas rate in the NEDOL program (without taking into account the treat gas rate to the solvent hydrotreater, which makes the difference even larger). This has an important impact on power requirements for the compressor and fuel requirements for slurry preheat furnace 207 and solvent hydrotreater preheat.
  • FIG. 3 of the drawings there is illustrated a second embodiment of the coal to aromatics flow scheme of the invention. Elements of the flow scheme that are the same as corresponding elements of the embodiment of FIG. 1 are identified with the same reference numbers as the corresponding elements of FIG. 1.
  • the primary difference between the embodiments of FIG's. 1 and 3 is that, in FIG. 3, the additional hydrogen required for the DCL system 103 and the upgrader 109 is produced by the H 2 Plant 303 rather than by the POX unit 111 used in FIG. 1.
  • the H 2 Plant 303 can be implemented as a steam naptha reformer (SNR) or a liquid POX unit, both of which are well known standard equipment in the art. For instance, SNR's are available from sources such as Akzo Nobel N.V.
  • liquid POX units are available from sources such as Haldor-Topsoe, Inc. or Lurgi GmbH. In either case, at least the C4- portion and if needed, part of the lighter portion of the C5+ portion of the 160°F- stream from the solvent extractor 123 is used as the feed to the H 2 Plant 303.
  • FIG. 4 of the drawings there is illustrated a third embodiment of the coal to aromatics process and system of the invention in which components that are the same as corresponding components in FIG's. 1 or 3 are labeled with the same reference numbers as such corresponding components in FIG's. 1 or 3.
  • the primary difference between the embodiments of FIG's. 4 and 3 is that, in FIG. 4, the feed to the H 2 Plant 303 that produces the additional hydrogen required for the DCL system 103 and the upgrader 109 is supplied by natural gas rather than by a the C1-C4 portion of the output from the solvent extractor 123.
  • the H 2 Plant 303 is implemented as an SMR.
  • the feed to the H 2 Plant 303 can also be from sources such as shale gas, or coal mine methane.
  • the SMR technology is utilized worldwide in refineries and is offered by many commercial vendors such as Haldor-Topsoe.
  • the embodiment of the invention illustrated in FIG. 1 is less expensive to implement and has a substantially higher thermal efficiency (between 60 and 65%) than the prior MTA systems (40- 45%).
  • POX of the DCL bottoms
  • the quantity of material being processed in the POX unit is greatly reduced.
  • the principle product is aromatics
  • the remaining exported byproduct is a C3/160°F stream from the solvent extractor 123. This stream would be converted to lighter paraffins if the alternative approach disclosed in U.S. Patent No. 5,472,593 is utilized, but will also require additional hydrogen for cracking.
  • the embodiment of the invention illustrated in FIG. 3 requires the lowest investment per ton of aromatics and also has the simplest flow scheme. Instead of bottoms POX, the lighter portion of the low value C1/160°F product is utilized as a feed for the production of H 2 . This allows use of lower cost H 2 generating technologies including liquid POX (no ash) or SNR.
  • a plant implementing the flow scheme of FIG. 3 consumes much of the lower value products that it produces, and therefore has a lower thermal efficiency (about 51.5%) than the embodiment of FIG. 1. Thus, there is a trade-off between higher thermal efficiency (FIG. 1), and lower investment, simpler, easier to operate plant (FIG. 3).
  • FIG. 4 is preferable where inexpensive natural gas is available.
  • H 2 is generated via SMR and the DCL bottoms are preferably sent to a CFB power plant for generation of power.
  • this embodiment would be economically preferable to the production of H 2 from the 160°F- stream.
  • This stream can better be sent to a Steam Cracking system for the production of olefins or aromatics.
  • This embodiment also has a substantially higher thermal efficiency (about 70%).

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)

Abstract

L'invention concerne un procédé de conversion de charbon en BTX, comprenant la conversion du charbon en un courant de produit à 600-700°F par liquéfaction directe. Ce courant de produit est soumis à un hydrocraquage et un hydrotraitement afin de produire un courant à 350°F, lequel est à son tour fractionné pour produire un courant à 160°F et un courant à 160/350°F contenant 85-90% de naphtènes. Le courant à 160/350°F est soumis à un reformage catalytique pour produire un courant de composés aromatiques et un courant paraffinique à 160°F. Le courant de composés aromatiques peut être séparé par distillation en courants de benzène, de toluène et de xylène.
PCT/US2014/032291 2013-04-02 2014-03-30 Procédés et dispositifs pour produire des composés aromatiques à partir de houille Ceased WO2014165415A2 (fr)

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US201361807423P 2013-04-02 2013-04-02
US61/807,423 2013-04-02
US14/229,904 2014-03-29
US14/229,904 US20140296595A1 (en) 2013-04-02 2014-03-29 Methods And Apparatus For Producing Aromatics From Coal

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