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Coal Gasification: Direct Applications and Syntheses of Chemicals and Fuels - 1987

S. S. Penner

University of California, San Diego

Section 1 is pages 1-148 and is 6.75MB.
Section 2 is pages 149-299 and is 6.74MB.
Section 3 is pages 300-413 and is 5.27MB.
Section 4 is pages 414-525 and is 4.81MB.

Abstract

xiii

Acknowledgements xiii

1

SUMMARY OF RESEARCH RECOMMENDATIONS 1

 

 2

OVERVIEW OF COAL-GASIFICATION R&D NEEDS 5
 

2.1

Introduction 5

2.2

Process Synthesis 6

2.3

Gasifiers for Electricity Generation 8

2.4

Gasification for Syngas Production 9

2.5

Gasification for Syntheses of Fuels and Chemicals 10

2.6

Gasifiers for Fuel Cells (FCs) 15

2.7

Gasification Catalysts 15

2.8

Gas Cleanup 16

2.9

Summary of Research Recommendations on Environmental Issues 21

2.10

Coal Beneficiation and Feed Preparation: Solids Processing 25

2.11

Applications of Advanced Diagnostics to Coal Gasification Systems 29

2.12

Fundamentals of Coal Conversion and Relation to Coal Properties 31
 

3

Gasification for Electricity Generation 37
  Sections 3.1 and 3.2 were written by S. B. Alpert, S. S. Penner and D. F. Wiesenhahn, Sec 3.3-3 by P.B. Tarman, and the remaining subsections of Sec 3.3, as well as Sec 3.4, by S. S. Penner and D. F. Wiesenhahn with advice in puts from correspondents identified in the subsections.

3.1

Integrated Coal-Gasification Combined Cycles (IGCC) 37
 

3.1-1

Introduction 37

3.1-2

IGCC System Status 38

3.1-3

Advantages IGCCs 42

3.1-4

Future Utilization of IGCCs 44
References for Section 3.1 44
 

3.2

The Cool Water IGCC 44
 

3.2-1

General Features 44

3.2-2

Process Description 45

3.2-3

Performance Results 47
References for Section 3.2 49
 

3.3

Selected Gasifiers for IGCC Plants 49
 

3.3-1

The Texaco Coal-Gasification Process (TCGP) 49

3.3-2

The Shell Coal-Gasification Process (SCGP) 53

3.3-3

The U-GAS Process 58

3.3-4

Other Gasifiers 73
References for Section 3.3 74
 

3.4

Research Recommendations for Improving Gasifiers 74
 

3.4-1

Fouling and Slagging 74

3.4-2

Corrosion and Fatigue 75

3.4-3

High-Temperature Sulfur Removal 76

3.4-4

Gasifiers for Low-Rank Coals 76

3.4-5

Low-Cost Gas Separation and Air Enrichment 76
References for Section 3.4 76
 

4

COAL GASIFICATION FOR SNG PRODUCTION 77
  This chapter has been written by Kermit E. Woodcock and Vernon L. Hill

4.1

Introduction 77
 

4.1-1

The Great Plains Coal Gasification Plant (GPCGP) 77

4.1-2

General Thermodynamic Considerations 78

4.1-3

General Flow Sheets 81
 

4.2

Advanced Gasification Technology for SNG 83
 

4.2-1

BGC/Lurgi Slagging Gasifier 84

4.2-2

KRW (Kellogg-Rust-Westinghouse) Ash-Agglomerating, Fluidized-Bed Gasifier 85

4.2-3

Rheinbraun AG, Hydrogasification 87

4.2-4

Catalytic Coal Gasification 90
 

4.3

Catalytic Methanation 90
 

4.3-1

Chemistry and Thermodynamics 90

4.3-2

Catalysis 92

4.3-3

Commercial Processes 94

4.3-4

Direct Methanation 94

4.3-5

Comflux Process (Fluid-Bed Methanation) 98

4.3-6

HICOM 99

4.3-7

Liquid-Phase Methanation 104
 

4.4

Acid-Gas Removal 105

 

4.4-1

Commercial Processes 105

4.4-2

Advanced Technologies 106
 

4.5

SNG Economics 110

4.6

Research and Development Needs 112
 

4.6-1

Engineering Development and Testing 112

4.6-2

Technology Base Data for Design 113

4.6-3

Basic Research Needs for Advanced Systems 114
References 114
 

5

GASIFICATION FOR THE SYNTHESES OF FUELS AND CHEMICALS 117
  This chapter has been written by W. O. Haag, J. C. Kuo and I. Wender

5.1

Catalytic Conversion of Synthesis Gas to Fuels and Chemicals 117
 

5.1-1

Introduction 117

5.1-2

Synthesis of Methanol and Higher Oxygenated Compounds 120

5.1-3

SG as a Source of Chemicals 139

5.1-4

Fischer-Tropsch Synthesis 144

5.1-5

Syntheses of Chemicals Using SG, CO or Methanol Plus Other Chemicals 160

5.1-6

Other Chemicals from SG, Methanol and CO; Emerging Process 164
 

5.2

Catalytic Processing of Synthesis-Gas-Derived Products 168
 

5.2-1

Introduction 168

5.2-2

Methanol-to-Gsaoline (MTG) 169

5.2-3

Methanol Conversion to Olefins and Diesel 173

5.2-4

Processing of Fischer-Tropsch Products 175
 

5.3

Interaction of Coal Gasifiers with Synthesis Gas Conversion Processes 179
 

5.3-1

Introduction 179

5.3-2

H2 + CO Partial Pressure Requirements 180

5.3-3

H2/CO Ratio Requirement 184

5.3-4

Purity Requirements for Synthesis Gas 187
 

5.4

Zeolites as Shape-Selective Catalysts 188
 

5.4-1

Introduction 188

5.4-2

Classification fo Zeolites 189
5.4-3 Intrinsic Catalytic Properties of Zeolites 194
5.4-4 Shape Selectivity 194
References 197
 

6

COAL GASIFICATION IN FUEL-CELL APPLICATION 207
 

6.1

Overview of FCs

207
 

This section has been written by A. J. Appleby

 
6.1-1 Introduction 207
6.1-2 The FC as a Direct Energy-Conversion Device 209
6.1-3 Alkaline Fuel Cells (AFCs) 213
6.1-4 Acid Fuel Cells 217
6.1-5 Molten Carbonate Fuel Cells (MCFCs) 221
6.1-6 Solid Oxide Fuel Cells (SOFCs) 226
6.1-7 Conclusions 229
 

6.2

Coal Gasifiers for FCs 230
  This section has been abstracted by S. S. Penner and D. F. Wisenhahn from viewgraphs presented by D. Rastler at the Second Technical Meeting of COGARN
6.2-1 The Site-Specific UPA Design 230
6.2-2 The Site-Specific SCE Design 234
6.2-3 Conclusions 236
6.2-4 Research Needs on Gasifier-PAFC Systems 239
6.2-5 Other Gasifier-FC Systems 239
References 239
 
7 USE OF CATALYSTS DURING GASIFICATION 243
  This chapter has been prepared by S. S. Penner and D. F. Wiesenhahn

7.1

Selected Examples of Current Research

243
  7.1-1 Introduction 243
7.1-2 Results from the 1985 International Coal Science Conference 244
7.1-3 Catalytic Conversions at Reduced Temperatures 249

References for Section 7.1

257
 

7.2

The Exxon Process for Catalytic Coal Gasification 258
  7.2-1 Process Features 258
7.2-2 Development Work 261
7.2-3 Fluid-Bed Slurry Dryer (FBSD) 266
7.2-4 Mechanisms of Catalysis and Selection of Alternative Catalysts 266
7.2-5 Environmental Aspects of CCG 270
7.2-6 Large Pilot Plant 271
References for Section 7.2 271
 

7.3

Recommended Research for Syngas Production from Coal 271
 

8

GAS-CLEANING PROCESSES FOR COAL GASIFICATION 273
  This chapter has been written by Robert A. Magee. The Appendix to this chapter has been written by J. F. Elliot.

8.1

Introduction

273

8.2

Gas Cleanup Systems

274

8.3

Quenching, Cooling and Heat Recovery 276

8.4

Removal of Particles, Aerosols and Inorganic Compounds 277

8.5

Acid-Gas Removal and Sulfur Recovery 278
  8.5-1 Solid Sorbents and In-Bed Desulfurization 279
8.5-2 Sulfur-Redox Processes 282
 
References 283
 
Appendix: Slag for In-Bed Sulfur Removal 285
 

9

ENVIRONMENTAL ISSUES 291
  This chapter has been written by Edward S. Rubin.

9.1

Introduction 291

9.2

Overview of US Regulatory Policy 291
  9.2-1 Trends in Environmental Regulation 291
9.2-2 Elements of Current Policy 292
9.2-3 Future Regulatory Directions 293
 
9.3 Environmental Emissions from Coal Gasification 299
  9.3-1 Process Overview 300
9.3-2 Recent Characterization 302
9.3-3 Methods of Environmental Control 319
 
9.4 Experience at Commercial Facilities 324
  9.4-1 The Great Plains Gasification Plant 324
9.4-2 The Cool Water Gasification Facility 325
 
9.5

Research Needs and Priorities

327
  9.5-1 Current Control Technology 328
9.5-2 Future Environmental Requirements 329
9.5-3 Advances Control Technology 332
 
References 333
 

10

COAL BENEFICIATION 335
  This chapter has been written by Suman P. N. Singh
10.1

Background

335
10.2

Current Commercial Practice

338
10.3

Recent Advances in Coal Cleaning

343
10.4

Conclusions

344
 
References 346
 

11

OPTICAL DIAGNOSTICS FOR IN SITU MEASUREMENTS IN COMBUSTION ENVIRONMENTS CONTAINING COAL PARTICLES

349
  This chapter has been written by D. R. Hardesty and D. K. Ottesen
 
Abstract 349
 
11.1 Introduction 350
11.2 Diagnostics Requirements 350
  11.2-1 Characteristics of Class I Flows 351
11.2-2 Diagnostics Considerations for Class I Flows 353
11.2-3 Characteristics of Class II Flows 355
11.2-4 Diagnostics Considerations for Class II Flows 355
 
11.3 Gas-Phase Temperature Measurement 356
  11.3-1 Raman Scattering Techniques 356
11.3-2 Fluorescence and Absorption Techniques 363
 
11.4 Gas-Phase Species Concentration Measurement 366
  11.4-1 Raman Scattering Techniques 366
11.4-2 Fluorescence and Absorption Techniques 367
 
11.5 Particle Size, Number Density and Temperature Measurements 370
  11.5-1 Single Particle Counter, SPC (Scattering) Instruments 371
11.5-2 Imaging Methods for Analysis of Particulates 381
11.5-3 Ensemble Methods for Analysis of Particulates 382
 
11.6 Velocity Measurements in Particle-Laden Flows 383
  11.6-1 Application of Laser-Doppler Velocimetry to Coal-Derived Flow 384
 
11.7 Particulate Composition Measurement by Laser-Spark Spectroscopy (LASS) 385
 
References 394
 

12

FUNDAMENTALS OF COAL CONVERSION AND RELATION TO COAL PROPERTIES 397
 

This chapter has been written by P. R. Solomon and J. M. Beer. The Appendix is by J.P. Longwell.

 
12.1 Introduction 397
12.2 Coal Characterization 399
  12.2-1 Organic Structure (Functional Groups) 399
12.2-2 Viscosity 400
12.2-3 Pyrolysis 400
12.2-4 Reactivity 400
12.2-5 Mineral Matter 401
 
12.3 Fundamental Processes in Gasification and Partial Gasification 402
  12.3-1 Heat Transfer 402
12.3-2 Pyrolysis Rates 406
12.3-3 Devolatilization: Formation of Gases, Condensables and Char 408
 
12.4

The Behavior of Coal Mineral in Gasification

423
  12.4-1 The Nature of Mineral Matter in Coal and Its Characteristics 423
12.4-2 Behavior During Heating 424
12.4-3 Mineralogical Transformations at High Temperatures 425
12.4-4 Ash Agglomeration 425
 
12.5 Mathematical Modeling 426
  12.5-1 Status of Model Development 426
 
12.6 Research Recommendations 429
  12.6-1 Coal Characterization 429
12.6-2 Fundamental Processes in Gasification and Partial Gasification 430
12.6-3 Mathematical Modeling of Gasification Processes 432
 
References 433
 
Appendix: Effect of CaO on Combined Fluidized-Bed Gasification and Pyrolysis 440
 

13

GAS SUPPLIES AND SEPARATION ASH DISPOSAL, MATERIALS FOR GASIFIERS 443
  13.1 Gas Supplies and Separation 443
 

This section has been abstracted by S. S. Penner and D. F. Wiesenhahn from viewgraphs and references supplies by A. Smith.

 
13.1-1 Introduction 443
13.1-2 Cryogenic Air Separation 444
13.1-3 The MOLTOX System 446
13.1-4 Other Air-Separation Systems 450
13.1-5 Research Needs 450
 
References for Section 13.1 451
 
13.2 Utilization and Disposal of Ash from Gasifiers 452
  This section has been written by S. B. Alpert.
 
13.2-1 Environmental-Impact Studies 454
 
13.3 Construction Materials for Coal Gasification 455
  This section has been written by M. T. Simmad
 
13.3-1 Introduction 455
13.3-2 High-Temperature Corrosion 455
13.3-3 Low-Temperature Corrosion 463
13.3-4 Erosive Wear 464
13.3-5 Mechanical Properties 465
13.3-6 Materials for Syngas Coolers of Slagging Gasifiers 468
13.3-7 Nuclear Heat Steam-Gasification of Coal 470
 
References for Section 13.3 475
 

14

INTRODUCTION TO COSTING 477
   
This chapter has been written by D. Pescarolo
 
APPENDIX

 

GENERAL REMARKS ON COAL-GASIFICATION SYSTEMS 483
 
This appendix has been prepared by S. S> Penner and D. F. Weisenhahn and is based on a presentation by R. Shinnar
 
A-1 Stoichiometry of Coal Conversion 483
A-2 Gasifier Efficiency 486
A-3 Fluidized-Bed Gasifiers 490
 
References 492
 
GLOSSARY OF SYMBOLS AND ABBREVIATIONS 493
 
FORMAL REVIEWS OF THE COGARN REPORT 499