Return to DOE Reports Table of Contents - D

Methanation Plant Design for HTGR Process Heat - September 1981.

Davis, C. R.

General Electric Company

In this pdf format, this document has 208 pages and is 5.37MB.

Table of Contents

 

Table of Contents

iii

List of Tables

ix

List of Figures

xi

List of Appendices

xiii

Abstract

xv

Acknowledgements

xvii

1.

Introduction

1-1

1.1

Background

1-1

1.2

Objectives

1-2

1.3

Assumptions

1-3

References

1-7

2.

Summary

2-1

2.1

Conclusions

2-1

2.1.1

Scaling the Reference Methanation System

2-1

2.1.2

Cost Estimates of the Reference Methanation System

2-2

2.2

Recommendations

2-3

2.2.1

Advanced Methanation Catalyst

2-3

2.2.2

Re-Evaluation of L/D ratio of Catalyst Beds

2-3

2.2.3

Scale Down the Reference Methanator Size

2-4

3.

Basis of Design

3-1

3.1

Application

3-1

3.2

Plant Inputs and Outputs

3-1

3.2.1

Syngas to Methane Conversion

3-1

3.2.2

Steam Generation

3-2

4.

Design Criteria

4-1

4.1

Design Requirements

4-1

4.1.1

180MWt Process Steam Methanation Plant

4-3

4.1.2

80MWt High Temperature Process Heat Plant

4-3

4.2

Plant Availability

4-3

4.3

Service Life

4-4

4.4

Design Safety Requirements

4-5

4.5

Inspection

4-6

4.6

Quality Control

4-6

4.7

Codes and Standards

4-9

References

4-11

5.

General Information

5-1

5.1

Desulfurization

5-1

5.1.1

Desulfurization Catalyst

5-2

5.1.2

Desulfurization Vessels

5-2

5.2

Methanation

5-3

5.2.1

Methanation Catalyst

5-4

5.2.2

Combination Methanator/Evaporator

5-7

5.2.3

Adiabatic Methanator

5-7

References

5-9

6.0

Reference Plant Design Description

6-1

6.1

Methanation Process System

6-1

6.1.1

Normal Operation

6-1

6.1.2

Partial Capacity Operation

6-13

6.2

Methanation Process Support System

6-13

6.2.1

Startup Procedure

6-14

6.2.2

Normal Shutdown Procedure

6-17

6.2.3

Hot Standby Operation

6-18

6.2.4

Emergency Shutdown

6-19

6.3

Methanation System Components

6-20

6.3.1

Syngas Heater

6-20

6.3.2

Desulfurizers

6-20

6.3.3

Combination Methanator/Evaporator (C M/E)

6-20

6.3.4

Superheater

6-23

6.3.5

Syngas Heater

6-23

6.3.6

Feedwater Heater No. 3

6-23

6.3.7

Methanator No. 2

6-27

6.3.8

Feedwater Heater No. 2

 

6.3.9

Methanator No. 3

6-27

6.3.10

Feedwater Heater No. 1

6-27

6.3.11

Remaining Syngas to Methane Components

6-30

6.3.12

Deaerator

6-30

6.3.13

Feedwater Pump

6-30

6.3.14

Steam Drum

6-32

6.3.15

Recycle Pump

6-30

6.3.16

Air Cooler

6-32

6.3.17

K. O. Drum

6-32

6.3.18

Product Gas Dryer

6-34

6.3.19

Recycle Gas Compressor

6-34

6.4

Support System Components

6-34

6.4.1

Startup Gas Heater Desulfurizer

6-34

6.4.2

Startup Gas Heater Methanators

6-35

6.4.3

Startup Heather Feedwater

6-35

6.4.4

Startup Nitrogen Supply

6-35

6.4.5

Condensate Storage Tank

6-36

6.4.6

K. O. Drum with Flare Stack

6-36

6.4.7

Emergency Power Supply

6-36

6.5

Materials

6-36

6.5.1

Combination Methanator/Evaporator (C M/E)

6-37

6.5.2

Superheater

6-37

6.5.3

Syngas Heater

6-37

6.6

Plant Arrangement Design

6-38

References

6-47

7.0

Plant Designs for Synfuel Processes

7-1

7.1

Coal Gasification

7-1

7.1.1

Syngas to Methane Conversion

7-1

7.1.2

Water to Superheated Steam Conversion

7-17

7.1.3

Nozzle and Pie Sizes

 

7.2

Oil Shale Reduction

7-18

7.2.1

Methanation Plant for PARAHO

7-18

7.2.2

Methanation Plant for TOSCO II

7-21

References

7-27

8.

Advanced Methanation Design Concepts

8-1

8.1

Isothermal Process Reactors

8-1

8.2

Monolithic Catalyst Reactors

8-1

8.3

Fluidized Bed Catalyst Reactors

8-2

References

8-3

9.

Research, Design and Development Recommendations

9-1

9.1

Immediate Engineering Activities (FY-1982 & 1983)

9-1

9.1.1

Computer Codes

9-1

9.1.2

Resize Methanation System

9-2

9.1.3

Other Design Needs

9-2

9.2

Short Range Engineering Activities (FY 1984-1985)

9-3

9.3

Long Range Engineering Activities (FY 1986-1989)

9-3

9.3.1

Monolithic Catalyst

9-3

10.

Cost Estimates

10-1

10.1

Capital Costs of References 40 MWt Methanator Plant

10-1

10.1.1

Methanation System Capital Costs

10-2

10.1.2

Support System Capital Costs

10-2

10.1.3

Plant Construction Costs

10-2

10.2

Operating Costs for Reference Methanator Plant

10-6

10.3

Plant Costs for Synfuel Applications

20-6

10.3.1

180 MWt Methanator System for Exxon Coal Gasification Process

10-6

10.3.2

80 MWt Methanator System for PARAHO Oil Shale Reduction Process

10-6

10.3.3

80 MWt Methanator System for TOSCO II Oil Shale Reduction Process

10-9

References

10-11