Direct coal liquefaction process

A process for the direct liquefaction of coal, which process is conducted in the absence of added carbon monoxide, and is performed in a coal liquefaction process plant comprising:

• a slurry mixing zone, a preheating zone, a liquefaction zone, a separation zone capable of separating a gaseous product stream from a liquid/solids product stream, an atmospheric fractionation zone, and a vacuum fractionation zone, which process comprises:
• a) introducing into said slurry mixing zone:
• i) coal having an average particle size of about 75 microns to about 600 microns and a moisture content from about 1 to about 4 wt. %;
• ii) effective amount of recycle non-donor solvent from said vacuum fractionation zone and non-donor bottoms from said atmospheric fractionation zone, wherein the ratio of non-donor solvent plus non-donor bottoms to coal is from about 2.5 to 1 to about 4 to 1:
• iii) a molybdenum-containing microcatalyst provided at a make-up rate that is equivalent to about 50 wppm to about 2 wt. % molybdenum on a moisture and ash free (MAF) feed coal basis;
• b) conducting the resulting slurry from step a) above at a pressure from about 1,500 psig to about 3000 psig and an effective amount of a treat gas containing at least 80 vol. % hydrogen, to said preheating zone wherein it is heated from a temperature from about 200° F. to 600° F. to a temperature of about 650° F.;
• c) conducting said heated slurry to said liquefaction zone wherein it is reacted at a temperature from about 700° F. to about 950° F. thereby producing reaction products;
• d) conducting said reaction products to a separation zone wherein a gaseous product stream is separated from a liquid/solids product stream;
• e) conducting said liquid/solids stream to said atmospheric fractionation zone, wherein it is fractionated to result in a C1 to C4 gaseous fraction, a C5/650° F. fraction, and a 650 F+ bottoms fraction;
• f) conducting an effective portion of non-donor 650° F.+ bottoms fraction from said atmospheric fractionation zone to said vacuum fractionation zone thereby resulting in a 1000° F.+ fraction and a non-donor 650° F. to 1000° F. solvent fraction from the vacuum fractionator;
• and leaving a remaining portion of said non-donor 650° F.+ fraction from said atmospheric fractionator;
• g) recycling the remaining portion of said non-donor 650° F.+ fraction from said atmospheric fractionation zone to the slurry mixing zone;
• and
• h) recycling at least a portion of said non-donor 650° F. to 1000° F. solvent fraction from said vacuum fractionation zone to said slurry mixing zone.