Executive Summary

ES-1

7

Introduction and Methodology

1

10

1.

Section 1 - Process Selection Rationale

1-1

11

1.1

Introduction

1-1

11

1.2

Process Description

1-2

12

1.2.1

Low-Pressure Syngas Process Description

1-3

13

1.2.2

High-Pressure Syngas Process Description

1-5

15

1.3

Discussion

1-6

16

1.3.1

Technologies Not Chosen

1-6

16

2.

Section 2 - Equipment Design and Cost Estimates

2-1

18

2.1

Introduction and Methodology

2-1

18

2.2

Key Design Assumptions

2-2

19

2.2.1

Sulfur and CO₂ Removal

2-2

19

2.2.2

Tar Reforming

2-2

19

2.2.3

Cyclones

2-3

20

2.2.4

Heat Integration

2-3

20

2.2.5

Methanol Compressor

2-3

20

2.3

Operating Costs and Utility Requirements

2-3

20

2.4

Differences with NREL Biomass to Hydrogen Design

2-6

23

2.4.1

Added Equipment to Chemicals Design

2-6

23

2.4.2

Increase in Steel Price

2-7

24

2.4.3

Engineering Assumptions

2-7

24

2.5

Changing Flows, Conditions, and Compositions

2-9

26

2.5.1

Flowrate Impacts

2-9

26

2.5.2

Composition Impacts

2-12

29

2.6

Follow-Up and Areas for Further Study

2-12

29

3.

Section 3 - Labor Requirements

3-1

31

3.1

Summary

3-1

31

3.2

Labor Requirements

3-1

31

3.3

Differences with Emery Energy 70 MWe Case

3-4

34

3.4

Differences with NREL Biomass to Hydrogen Case

3-4

34

4.

Appendix A - High-Pressure Syngas Design Case PFDs

A-1

36

5.

Appendix B - Low-Pressure Syngas Design Case PFDs

B-1

46

6.

Appendix C - Equipment Lists and Data Sheets

C-1

57

7.

Gas Cleanup Technologies Evaluated

D-1

103

7.1

D.1 Introduction

D-1

103

7.2

D.2 Particulate Removal Technologies

D-1

103

7.3

D.3 Tar Removal Technologies

D-5

107

7.4

D.4 Acid Gas Removal Technologies

D-7

109

7.5

D.5 Ammonia, Alkali, and Other Contaminants

D-13

115