Apparatus for liquefaction of carbonaceous material

Abstract

A carbonaceous material liquefaction apparatus which uses a nozzle assembly to supply a pressurised liquid towards a carbonaceous material as a high velocity liquid. A supply line ( 46, 39 ) supplies the high pressure liquid to the nozzle assembly ( 38 ). The high velocity liquid reacts with the carbonaceous material ( 35 ) in a reaction zone ( 40 ) to produce a processed carbonaceous material. A product return line ( 34, 42 ) returns the processed carbonaceous material and entrained liquid to a processing plant. The processing plant comprises a heat exchanger ( 44 ) to transfer heat from the product return line to the supply line, a high pressure pump ( 48 ) to provide the high pressure liquid to the supply line, a separator ( 52 ) in the product return line downstream of the heat exchanger to separate gas ( 54 ) and oil ( 56 ) product from the entrained liquid, at least part of the liquid ( 58 ) being recycled ( 64 ) to the high pressure pump. The reaction can be carried out in-situ or in an above ground reaction chamber ( 70 ).

1 . A carbonaceous material liquefaction apparatus comprising a nozzle assembly to supply a pressurised liquid with superheated or supercritical properties towards a carbonaceous material as a high velocity liquid, a supply line to supply the high pressure liquid to the nozzle assembly, the high velocity liquid reacting with the carbonaceous material to produce an upgraded or liquefied carbonaceous material, a product return line to return the processed carbonaceous material and entrained liquid to a processing plant, the processing plant comprising a heat exchanger to transfer heat from the product return line to the supply line, a high pressure pump to provide the high pressure liquid to the supply line, a separator in the product return line downstream of the heat exchanger to separate gas and oil product from the processed carbonaceous material and entrained liquid, and a recycle line to transfer at least part of the liquid from the separator to the high pressure pump. 
     
     
         2 . A carbonaceous material liquefaction apparatus as in  claim 1  further comprising an injection apparatus downstream of the high pressure pump to supply initiation chemicals and catalysts to the high pressure liquid supply line. 
     
     
         3 . A carbonaceous material liquefaction apparatus as in  claim 1  for above ground carbonaceous material liquefaction further comprising a reaction vessel, means to supply a charge of the carbonaceous material to the reaction vessel and the product return line being connected to the reaction vessel, the nozzle assembly directing the high velocity liquid with superheated or supercritical properties towards the charge of the carbonaceous material. 
     
     
         4 . A carbonaceous material liquefaction apparatus as in  claim 3  further including means to withdraw spent residue of the carbonaceous material from the reaction vessel. 
     
     
         5 . A carbonaceous material liquefaction apparatus as in  claim 3  where in the nozzle assembly comprises a plurality of nozzles. 
     
     
         6 . A carbonaceous material liquefaction apparatus as in  claim 1  for in-situ carbonaceous material liquefaction wherein the product return line comprises a well casing and the supply line comprises a high pressure tubing within the well casing with the nozzle assembly attached to the tubing to enable the fluid within the tubing to exit the nozzle with a reduced pressure and increased velocity and so retaining the properties of superheated or supercritical water for a period of time and the carbonaceous material is selected from coal, oil shale and tar sands. 
     
     
         7 . A carbonaceous material liquefaction apparatus as in  claim 6  wherein the nozzle assembly is able to be directed towards the carbonaceous material in an in-situ reaction zone. 
     
     
         8 . A carbonaceous material liquefaction apparatus as in  claim 6  where in the nozzle assembly comprises a plurality of nozzles radiating the high velocity liquid towards the in-situ carbonaceous material. 
     
     
         9 . A carbonaceous material liquefaction apparatus as in  claim 1  wherein the high pressure pump to provide the high pressure liquid to the supply line provides the liquid at pressures of from 15 MPa and 35 MPa. 
     
     
         10 . A carbonaceous material liquefaction apparatus as in  claim 1  further including a bleed off excess entrained liquid from the separator. 
     
     
         11 . A carbonaceous material liquefaction apparatus as in  claim 1  wherein the separator comprises a multi-stage separator, a first separator comprising a flash separator to separate gases from the processed carbonaceous material and entrained liquid, a second separator comprising an oil-liquid separator to separate oil from the processed carbonaceous material and entrained liquid and a filter to separate particulate material from the processed carbonaceous material and entrained liquid. 
     
     
         12 . A carbonaceous material liquefaction apparatus as in  claim 1  wherein the upgraded or liquefied carbonaceous material in the product return line is in whole or in part substantially in a vapour phase, the vapour phase also entraining liquid and solid particles or droplets and whereby vapour phase recovery providing a more efficient recovery mechanism for upgraded or liquefied carbonaceous material than a conventional liquid phase recovery mechanism. 
     
     
         13 . A carbonaceous material liquefaction apparatus as in  claim 1  wherein the superheated or supercritical properties of the water are maintained for a period of time after exiting the nozzle assembly thereby enabling liquefaction reactions to occur upon contact of the water with supercritical properties and the carbonaceous material. 
     
     
         14 . A carbonaceous material liquefaction apparatus as in  claim 6  wherein the nozzle assembly comprises a nozzle or nozzles are attached to a tubing or supply line that may be moved within the carbonaceous material and wherein such movement controlled from surface.