Catalyst deactivation in direct coal liquefaction: a comparative study of Wilsonville runs. [Integrated Two-Stage Liquefaction (ITSL) mode; Doubly Integrated Two-Stage Liquefaction (DITSL) mode; Reconfigured Integrated Two-Stage Liquefaction (RITSL) mode]

Catalyst samples from Wilsonville runs 242, 246 and 247 have been extensively characterized and tested to determine the effects of different coals and process configurations on the causes and rates of catalyst deactivation. The two coals used in these runs were Illinois No. 6 Burning Star bituminous coal and Wyodak Clovis Point subbituminous coal. Process configurations used in these runs included the Integrated Two-Stage Liquefaction (ITSL) mode, the Doubly Integrated Two-Stage Liquefaction (DIRSL) mode and the Reconfigured Integrated Two-Stage Liquefaction (RITSL) mode. Although catalyst deactivation, as determined by model compound testing, was substantial in all of these runs, only small differences in catalyst properties were observed. RITSL processing resulted in the greatest initial losses of both hydrogenation activity and hydrodesulfurization activity. These high losses were due to the greater buildup of carbonaceous material on these catalysts probably due to the heavier hydrotreater feed in RITSL processing. After the initial high losses, activities of catalysts from the three runs continued to decrease with catalyst age at varying rates depending on the amount of contaminant metals present. The fastest rate was for catalysts from ITSL processing of Illinois No. 6 coal and the slowest was for catalysts from combined DITSL/ITSL processing ofmore » Wyodak coal. 2 refs., 15 figs.« less