Coal Solvent Extraction for High-Value Chemical Conversion
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Solution Overview
Problem
There is a need for systems and methods that can effectively convert coal into high-value products, exceeding the value of coal-based energy produced via combustion, while considering yields, efficiency, and the production of goods with desirable performance attributes.
Innovation Solution
Integrated thermochemical processes involving solvent extraction, chemical reactions, and separation methods are used to deliberately decompose and convert coal into a variety of high-value products, including chemicals, polymer composites, and building materials, with tunable yields and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional coal conversion technology is used to produce coal tars and hydrocarbon products, then fuel and petrochemical feedstocks can be manufactured, but the process produces appreciable quantities of solid porous carbon bi-products with high sulfur content that require further refinement
Solution Approach 1:
The patent applies extraction by selectively removing sulfur-containing compounds and other impurities from the solid porous carbon bi-products through chemical treatment processes. This separates the harmful sulfur content from the valuable carbon products, allowing the carbon products to be used without extensive further refinement while maintaining high yields of coal tar and hydrocarbon products.
2Use of energy by moving object
If coal is combusted to generate energy, then energy production is achieved, but the value is limited compared to potential chemical and material products
Solution Approach 1:
The patent transforms the utilization parameters of coal by shifting from thermal energy conversion (combustion) to chemical conversion processes. This includes controlling temperature, pressure, and chemical environment to produce high-value chemicals, polymers, and carbon materials, thereby increasing the value obtained per unit of coal feedstock while maintaining energy efficiency through optimized reaction conditions.
3Adaptability or versatility
If solvent extraction and pyrolysis processes are combined to produce high-value products, then diverse intermediate and finished products can be generated, but the process system becomes highly branched and complex
Solution Approach 1:
The patent implements multi-functional processing units that can handle multiple operations within a single system. The solvent extraction and pyrolysis processes are integrated into unified reactors and separation systems that can produce diverse product streams (chemicals, polymers, carbon materials) through adjustable operating parameters rather than requiring completely separate process lines, thereby reducing overall system complexity while maintaining product diversity.
4Manufacturing precision
If solid porous carbon bi-products are further refined to improve purity and remove undesirable elements, then product quality increases, but additional processing steps and costs are incurred
Solution Approach 1:
The patent performs preliminary removal of sulfur and other impurities during the main conversion processes (solvent extraction and pyrolysis) rather than requiring extensive post-processing. Chemical treatments are applied in-line during product formation to prevent impurity accumulation, thereby achieving high purity solid porous carbon products with minimal additional refinement steps and reduced overall process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These processes achieve significant conversion of coal into valuable products, with yields exceeding 30% dry basis and up to 60% in some embodiments, thereby increasing the value and demand for intermediate, derivative, and finished products relative to the feedstock.
Implementation Method 1
contacting the coal-based feedstock with one or more solvents under solvent treatment conditions for generating a soluble phase product
Implementation Method 2
chemical processes that convert coal components into new chemical species such as by hydrogenation reaction, aromatization reaction
Implementation Method 3
chemical processes that convert coal components into new chemical species such as by hydrogenation reaction, aromatization reaction
Implementation Method 4
fractionating the soluble phase product generating at least two fractions under conditions such that at least one of the fractionated products is the high value product
Data Source
AI summary
Described herein are integrated thermochemical processes for the deliberate decomposition, extraction and conversion of coal into high-value products and goods via solvent extraction, chemical reaction and/or separation. The described systems and methods are versatile and may be used to generate a variety of intermediate, derivative and finished high value products including chemicals (aromatics, asphaltenes, naphthalenes, phenols and precursors for the production of polyamides, polyurethanes, polyesters, graphitic materials), polymer composite products (resins, paints, coatings, adhesives), agricultural materials, building materials, carbon fiber, graphene products and other materials that are substantially more valuable that the energy generated via combustion.