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