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ANL/CES/TE 79-2

Special Distribution

 

High-BTU Coal Gasification Processes

 

by

Christopher F. Blazek

Nathaniel R. Baker

Raymond R. Tison

Institute of Gas Technology

 

Project Manager

Charles H. Gartside III

Energy and Environmental Systems Division

Argonne National Laboratory

 

January 1979

 

 

 

CONTENTS

 

                                                                                                                                                Page

Foreword                                                                                                                                 vi

Abstract                                                                                                                                   viii

Summary                                                                                                                                  xiv.A.I

1 Introduction                                                                                                                           1

2 Standard Practice                                                                                                                  4

            2.1 Applicable Codes and Standards                                                                            4

            2.2 Standard Ratings                                                                                                    4

            2.3 Derating Factors                                                                                                     4

                        2.3.1 Moisture                                                                                      4

                        2.3.2 Volatile Matter                                                                                        5

                        2.3.3 Fixed-Carbon Content                                                                             5

                        2.3.4 Sulfur Content                                                                                         5

                        2.3.5 Ash                                                                                                         6

3 Process Description                                                                                                               8

            3.1 Fixed- or Moving-Bed Reactors                                                                             8

                        3.1.1 General Discussion                                                                                  8

                        3.1.2 The Lurgi Process                                                                                    9

            3.2 Entrained Flow Reactors                                                                                         13

                        3.2.1 General Discussion                                                                                  13

                        3.2.2 The Bi-Gas Process                                                                                 13

            3.3 Fluidized-Bed Reactors                                                                                          15

                        3.3.1 General Discussion                                                                                  15

                        3.3.2 The Syuthane Process                                                                              15

                        3.3.3 The Cogas Process                                                                                  17

                        3.3.4 The Steam-Oxygen Hygas Process                                                          19

                        3.3.5 The IGT Steam-Iron Hygas Process                                                        21

4 Material Balance                                                                                                                    26

            4.1 Primary Material Input/Output                                                                                 26

4.2 Material Specifications                                                                                                        28

            4.3 Product Material Specifications                                                                               32

                        4.3.1 Lurgi Process (Single-Feed Case)                                                            32

                        4.3.2 Bi-Gas Process                                                                                       33

                        4.3.3 Synthane Process                                                                                    34

                        4.3.4 Cogas Process                                                                                        35

                        4.3.5 Steam-Oxygen Hygas Process                                                                 36

                        4.3.6 Steam-Iron Hygas Process                                                                      37

5 Energy Balance                                                                                                                      38

            5.1 General Discussion                                                                                                 38

            5.2 Energy Input/Output                                                                                               38

6 Environmental Effects                                                                                                             42

            6.1 General Discussion                                                                                                 42

            6.2 Thermal Discharges                                                                                                42

            6.3 Noise Attenuation                                                                                       43

            6.4 Aesthetics                                                                                                               43

            6.5 Gaseous Effluents                                                                                       43

            6.6 Aqueous Effluents                                                                                       47

            6.7 Solid Wastes                                                                                                          49

7 Operating Requirements                                                                                                         51

            7.1 Considerations                                                                                                        51

            7.2 Operating Personnel                                                                                               52

8 Maintenance And Reliability                                                                                       54

            8.1 General                                                                                                                  54

            8.2 Maintenance Requirements                                                                                     54

            8.3 Plant Life And Reliability                                                                             55

9 Cost Considerations                                                                                                  56

            9.1 General                                                                                                                  57

            9.2 Capital Cost                                                                                                           57

            9.3 Annual Operating Cost                                                                                           58

            9.4 Saleable Product Output Rates                                                                               60

References                                                                                                                               63