Donald E Malone

US Patent:

7052661, May 30, 2006

Filed:

Jan 21, 2003

Appl. No.:

10/348112

Inventors:

Donald P. Malone - Grayson KY, US

Assignee:

Envi Res LLC - Lexington KY

International Classification:

C01G 11/00
C01G 13/00
C01G 9/00
B01D 47/00
B01J 8/00

US Classification:

423210, 4232105, 423 99

Abstract:

A process for removing mercury from a feed of coal, heavy oil or other mercury contaminated material is disclosed. The feed is thermally decomposed, preferably within, or above, a molten metal bath under reducing conditions, to produce a vapor product and non-vapor decomposition products, such as carbon, which dissolve in the molten metal bath. Mercury, primarily in the form of elemental metal vapor, is removed with the vapor product, cooled and passed over a mercury adsorbent to recover mercury from the gas. The decomposition products are burned, e. g. , by at least periodic oxidation of the molten metal bath. Preferably a HyMelt reactor, with a bath of molten iron, operating at superatmospheric pressure, thermally decomposes the feed. The process permits efficient mercury removal and recovery from coal using conventional adsorbents, such as activated carbon.

US Patent:

7150822, Dec 19, 2006

Filed:

Aug 14, 2004

Appl. No.:

10/918916

Inventors:

Donald P. Malone - Grayson KY, US

Assignee:

DTX Technologies LLC - Lexington KY

International Classification:

C10M 175/00
C10G 33/00

US Classification:

208179, 208187

Abstract:

A process for heating thermally unstable or difficult to heat liquid feeds, e. g. , used lubricating oil (ULO) to dehydrate and/or recover distillable components therefrom, is disclosed. The liquid feed is heated by direct contact heat exchange with molten metal, preferably maintained as a bath, operating at a temperature above the boiling point of water and below 600 C. The liquid feed is heated and typically at least partially vaporized in, or above, or by contact with the molten metal to produce a heated liquid. When ULO contaminated with water is the feed, the vapor product of the process will comprise water vapor and/or distillable hydrocarbons. ULO additive decomposition products, such as carbon, may be removed as a solid, semi-solid or liquid residual phase from contact with the molten metal.

US Patent:

7220348, May 22, 2007

Filed:

Jul 27, 2004

Appl. No.:

10/899976

Inventors:

Donald P. Malone - Grayson KY, US
Howard F. Moore - Ashland KY, US
Melvin D. Kiser - Huntington WV, US

Assignee:

Marathon Ashland Petroleum LLC - Findlay OH

International Classification:

C10C 3/00
C10C 1/00

US Classification:

208 41, 208 6, 208 39, 208 40, 208 42, 208 43, 208 44, 208113, 516 38

Abstract:

The present invention provides a way to increase the softening point of heavier hydrocarbons in a relatively low cost and low pressure process using superheated steam to i) increase the carbon yield of the heavier hydrocarbons, while simultaneously ii) removing volatile components with a steam stripping process.

US Patent:

7241377, Jul 10, 2007

Filed:

Aug 16, 2004

Appl. No.:

10/918956

Inventors:

Donald P. Malone - Grayson KY, US

Assignee:

DTX Technologies, LLC - Lexington KY

International Classification:

C10M 175/00
C10G 7/00

US Classification:

208179, 208177, 208347

Abstract:

A process for heating thermally unstable or difficult to heat liquid feeds, e. g. , used lubricating oil (ULO) to dehydrate and/or recover distillable components therefrom, is disclosed. The liquid feed is heated by direct contact heat exchange with molten salt, preferably maintained as a bath, operating at a temperature above the boiling point of water and below 600 C. The liquid feed is heated and typically at least partially vaporized in, or above, or by contact with the molten salt to produce a heated liquid. When ULO contaminated with water is the feed, the vapor product of the process will comprise water vapor and/or distillable hydrocarbons. ULO additive decomposition products, such as carbon, may be removed as a solid, semi-solid or liquid residual phase from contact with the molten salt.

US Patent:

7318890, Jan 15, 2008

Filed:

Oct 8, 2004

Appl. No.:

10/962022

Inventors:

Donald P. Malone - Grayson KY, US

Assignee:

DTX Technologies LLC - Lexington KY

International Classification:

C10C 3/00
C10C 3/10

US Classification:

208 41, 208 22, 208 40, 208 44, 208 49, 208 50, 208 67, 208 72, 208 85, 208131

Abstract:

A process for fractionating crude pitch by direct contact heating with molten metal is disclosed. The crude pitch, which may contain water, contaminants and/or distillables is heated by direct contact heat exchange with molten metal, preferably maintained as a metal continuous bath, operating at a temperature of 100 to 600 C. The molten metal heating zone is maintained at a temperature and pressure sufficient to vaporize a desired amount of contaminants or volatile material from crude pitch to produce pitch product having a desired softening point. New pitch materials, having a softening point above those achievable by conventional techniques, are also produced.

US Patent:

7318891, Jan 15, 2008

Filed:

Oct 8, 2004

Appl. No.:

10/962023

Inventors:

Donald P. Malone - Grayson KY, US

Assignee:

DTX Technologies LLC - Lexington KY

International Classification:

C10C 3/06
C10C 3/10

US Classification:

208 41, 208 22, 208 40, 208 44, 208 49, 208 50, 208 67, 208 72, 208 85, 208131

Abstract:

A process for producing pitch from pitch precursors, such as wood tar, coal tar or petroleum fractions is disclosed. Direct contact heat exchange of the pitch precursor with molten metal, preferably maintained as a metal continuous bath, heats the pitch precursor to a temperature sufficient to induce thermal polymerization reactions and produce a pitch product.

US Patent:

7341656, Mar 11, 2008

Filed:

Jul 26, 2004

Appl. No.:

10/898836

Inventors:

Donald P. Malone - Grayson KY, US
Patricia K. Doolin - Ashland KY, US
Howard F. Moore - Ashland KY, US

Assignee:

Marathon Ashland Petroleum Co. LLC - Findlay OH

International Classification:

C10G 27/04
C10G 27/00
C10C 1/00
C10C 1/04
C10C 3/00
C10C 3/04
C10C 3/06

US Classification:

208 4, 208 6, 208 39, 208 41, 208 42, 208 43

Abstract:

The present invention provides a way to process heavier hydrocarbons in a relatively low cost and low pressure process using a combination of superheated steam and at least one reaction gas to i) promote oxidation and thermal reaction of heavier hydrocarbons, while simultaneously ii) removing volatile components with a steam stripping process.

US Patent:

55773460, Nov 26, 1996

Filed:

Apr 13, 1995

Appl. No.:

8/421102

Inventors:

Donald P. Malone - Grayson KY

Assignee:

Ashland Inc. - Ashland KY

International Classification:

C10J 306

US Classification:

48197R

Abstract:

A plural-zone molten metal iron gasifier for converting feeds containing hydrogen and carbon, such as propane, solvent deasphalted pitch, etc. , into substantially pure hydrogen and CO/CO. sub. 2 streams under pressure by incorporating carbo into the molten metal in a first zone or vessel, then circulating the molten metal into contact with an oxygen-containing gas in a second zone or vessel. Preferably hydrogen is primarily produced in a third zone or vessel, and carbon oxides in a second zone or vessel. A one-meter diameter vessel can produce 20 million standard cubic feet per day of hydrogen at a pressure in the range 2 to 50 atm from methane using this invention.