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Evaluation of Pollution Control in Fossil Fuel Conversion Process.
Final Report - 1976

Magee, E. M.

Exxon Research and Engineering Company

Table of Contents (699kb)

Acknowledgements

1

Introduction (337kb)

1

  1.1 Background

1

1.2 Literature survey

2

  1.1.1

Trace Elements in Fossil Fuels

2

1.1.2

Coal and Crude Oil Conversion/Treatment Processes

2

1.3 Discussion with Process Developers

3

1.4 Trips to Commercial Plants

3

1.5 Preliminary Process Designs

3

1.6 Analytical Test Plan

4

1.7 Transient Pollutants

4

2

Coal Gasification Plants (2.12MB)

7

  2.1 General Gasification Description

7

2.2

Coal Storage and Preparation

11

 

2.2.1

Description of Coal Storage and Preparation

11

2.2.2

Effluents to Air from Coal Storage and Preparation

14

2.2.3

Liquids and Solids Effluents from Coal Storage and Preparations

15

2.2.4

Process Alternatives

15

2.3

Gasification and Quench Sections

16

 

2.3.1

Gasifiers and Operating Conditions

16

2.3.2

Gasifier Effluents to Air

18

2.3.3

Liquid and Solid Effluents

18

2.3.4

Process Alternatives

18

2.4

Shift Conversion and Cooling

23

 

2.4.1

Description of Shift Conversion

23

2.4.2

Effluents to Air from shift Conversion and Cooling

23

2.4.3

Liquids and Solid Effluents from Shift Conversion and Cooling

24

2.4.4

Process Alternatives in Shift Conversion and Cooling

24

2.5

Acid Gas Removal

24

 

2.5.1

Description of Acid Gas Removal

24

2.5.2

Effluents to Air From Acid Gas Removal

28

2.5.3

Liquids and Solid Effluents from Acid Gas Removal

28

2.5.4

Process Alternatives in Acid Gas Removal

28

2.6 Methanation Section

29

 

2.6.1

Description of the Methanation Section

29

2.6.2

Effluents to Air from the Methanation Section

30

2.6.3

Liquids and Solid Effluents

30

2.6.4

Process Alternatives in Methanation

30

2.7 Compression and Drying

30

2.8 Final Product and Gas

31

2.9 Oxygen Plants

31

2.10 Sulfur Recovery

31

  2.10.1

Description of Sulfur recovery

31

2.10.3

Effluents from Sulfur Recovery

34

2.11 Ash and Solids Disposal

36

  2.11.1

Description of Ash and Solids Disposal

36

2.11.2

Effluents to Air from Solids Disposal

36

2.11.3

Liquids and Solids Effluent from Solids Disposal

36

2.11.4

Process Alternatives in Solids Disposal

38

2.12 Wastewater Treatment

38

2.13 Power and Steam Generation

43

  2.13.1

Alternatives in Power and Steam Generation

43

2.13.2

Effluents from Power and Steam Generation

45

2.14 Cooling Water System

45

2.15 Raw Water Treatment

48

2.16 Miscellaneous Plant Sections

48

  2.16.1

CO2 Acceptor Regeneration

48

2.16.2

Low BTU Fuel Gas Production in the Lurgi Process

48

2.16.3

Low BTU Fuel Gas Production in the HYGAS Process

51

3

Coal Liquefaction Plants (926kb)

55

  3.1 General Description of Coal Liquefaction Plants

55

3.2 Main Liquefaction Train

57

  3.2.1

Coal Storage and Preparation

57

3.2.2

Coal Liquefaction

57

3.2.3

Products Separation

64

3.2.4

Hydrotreating

64

3.3 Hydrogen Production

64

3.4 Auxiliary Facilities

68

  3.4.1

Oxygen Plants

68

3.4.2

Acid Gas Removal

68

3.4.3

Sulfur Recovery

72

3.4.4

Ash and Solids Disposal

72

3.4.5

Wastewater Treatment

72

3.4.6

Electricity and Steam Generation

72

3.4.7

Cooling Water System

77

3.4.8

Raw Water treatment

77

4

Coal Treating (114kb)

87

  4.1 Description of the Meyers Process

87

4.2 Feed, Products, Utilities and Effluents of the Meyers Process

87

5

Thermal Efficiency (356kb)

92

  5.1 General

92

5.2 Non-Process Related Factors Affecting Thermal Efficiency

92

5.3 Thermal Efficiencies of Processes Investigates

94

5.4 Detailed Losses in Thermal Efficiency

94

6

Stream Analysis for Trace Elements and Other Potential Pollutants (1.24MB)

99

  6.1 General

99

6.2 The Fate of Trace Elements in Coal Conversion

99

  6.2.1 Trace Elements in Coals

99

6.2.2 Trace Elements in Coal Feed to Processes in this Study

105

6.2.3 Fate of Trace Elements in Coal

105

6.3 Trace Elements in Petroleum and Shale

108

  6.3.1 Correlations Indicated

108

6.3.2 New Data Required

109

6.4 Trace Compounds Formed in Coal Conversion

109

6.5 Data Acquisition

113

  6.5.1 Analyses to be made

113

6.5.2 Analytical Techniques

113

6.5.3 Coal Conversion Streams to be sampled

113

6.6 Analysis of Streams from Commercial and Development Scale Gasification Plants

121

7 Technology Needs (251kb) 133
  7.1 Trace Elements in Coal 133
7.2 Trace Elements and Other Potential Pollutants in Coal Conversion 134
7.3 Improvements in Thermal Efficiency 135
8 Transient Pollutants (2.51MB) 137
  8.1 General 137
8.2 Startup 138
8.3 Shutdown 143
8.4 Upsets 153
  8.4.1 General 153
8.4.2 Coal Storage and Preparation 154
8.4.3 Crushing and Screening 155
8.4.4 Drying 155
8.4.5 Pretreatment 156
8.4.6 Coal Conversion 158
 

8.4.6.1

Gasification 158

8.4.6.2

Liquefaction 160
8.4.7 Shift and Cooling 162
8.4.8 Acid Gas Removal 163
8.4.9 Methanation, Compression and Drying 164
8.4.10 Sulfur Plant 165
8.4.11 Oxygen Plant 166
8.4.12 Solids Disposal 167
8.4.13 Water Treatment 167
8.4.14 Steam and Power Supply 172
8.5 Maintenance 174
8.6 Chemicals and Catalyst Replacement 175
8.7 Storage of Products and Byproducts 176
8.8 Design Considerations 176
9 Bibliography (353kb) 179

Appendices (5.65MB)