Gasification Product Improvement Facility (GPIF) - Conceptual Design Report

Gasification Product Improvement Facility (GPIF)
Conceptual Design Report - September 1994

Sadowski, R. S. and Skinner, W. H. - CRS Sirrine Engineers, Inc.
House, L. S. and Duck, R .R. - CRS Sirrine Engineers, Inc.
Lisauskas, R.A. and Dixit, V. J. - Riley Stoker Corporation
Morgan, M. E. and Johnson, S. A. - PSI PowerServ
Boni, A. A. - PSI-Environmental Instr. Corp.

Part 1, Pages 1 - 77, 4.54 MB
List of Drawings					iii
List of Figures					iv
List of Tables					v
1.0	Summary				1
2.0	Process & Operation				5
		2.0.1	Anticipated Throughput Capacity		7
		2.0.2	Increasing Performance & Operating Safety		9
	2.1	Process Descriptions			11
		2.1.1	Functional Descriptions		11
		2.1.2	Process Flow Sheets		26
		2.1.3	Equipment Specifications		28
			2.1.3.1	Materials of Construction	28
			2.1.3.2	Size of Significant Vessels	29
		2.1.4	Functional Descriptions of Test Facility – Phase II		29
	2.2	Operating Requirements			30
		2.2.1	Operating Summary		30
		2.2.2	Predicted Plant Emissions (Gaseous, Liquid, Solid)		52
		2.2.3	Utility Consumption		58
			2.2.3.1	Normal	28
			2.2.3.2	Special	61
		2.2.4	Feed Flow Rates		61
		2.2.5	Product Flow Rates		63
		2.2.6	Process Mass & Energy Balances		64
		2.2.7	Major Operating Parameters		68
3.0	Conceptual Design				71
	3.1	Plant Description			71
	3.2	Coal Preparation & Feed System			71
	3.3	Compressors & Air Handling System			71
	3.4	PyGas™ Gasifier, Ash Handling, Fines Control			76
	3.5	Steam Generation, Water Treatment			76
Part 2, Pages 78 - B-33, 3.00 MB
	3.6	Piping, Electrical			78
		3.6.1	Piping Systems: Approximate Flows & Conditions		78
		3.6.2	Electrical Requirements		81
	3.7	Disposal of Fuel Gas			87
	3.8	Emission Control System			88
	3.9	Process Steam Characterization			88
	3.10	Fuel Gas Monitoring, Data Acquisition, Process Control Instrumentation			89
	3.11	Host Site Interfaces			98
4.0	Site Requirements, Revised Cost & Schedule				101
	4.1	Site Preparation Requirements			101
		4.1.1	Foundations/Pads Designs		101
		4.1.2	Steel, Support Structure, Layout		102
		4.1.3	Process Building & Area Major Features		102
		4.1.4	Office Configuration		105
		4.1.5	Utility Service		105
	4.2	Revised Construction Cost Estimate			105
		4.2.1	Value Engineering Cost Reduction Potentials		107
		4.2.2	Recommended Project Scope Changes		108
	4.3	Schedule for Detail Design & Construction			109
		4.3.1	Long Lead Items Descriptions		109
		4.3.2	Anticipated Time Requirements		111