Part 1

1.0

Introduction to the Report

1-1

1.1

Introduction to the Summary

1-2

1.2

Summary of Hydrogasification in the 4-Inch PDU

1-3

1.2.1

Product Gas Composition and Trace Components

1-6

1.2.2

Char Compositions

1-7

1.2.3

Liquid Products

1-8

1.3

Summary of Pilot Plant Development

1-9

1.4

Summary of Hydrogen Generation

1-13

1.4.1

Hydrogen for the HYGAS Process

1-13

1.4.2

Electrothermal/300 kW (6-inch) Unit

1-15

1.4.3

Electrothermal/2.25 MW (30-inch) Unit

1-16

1.4.4

Steam-Oxygen Gasification

1-16

1.4.5

Steam-Iron Gasification

1-19

1.4.6

References Cited

1-22

1.5

Summary of Methanation

1-23

1.6

Summary of Coal and Char Characterization

1-25

1.6.1

Petrography and Related Studies

1-25

1.6.2

Miscellaneous Support Studies

1-26

1.6.3

Calorimetry

1-26

1.6.4

Kinetics of Coal Gasification

1-28

1.6.5

References Cited

1-29

1.7

Summary of Coal Pretreatment in the 10-Inch PDU

1-30

1.8

Summary of Commercial Plant Design

1-31

1.9

Summary of Process Economics

1-33

1.9.1

Discussion

1-33

1.9.2

Bibliography

1-34

1.10

High-Btu Bibliography

1-35

1.11

Associated Invention Disclosures

1-66

2.0

Summary of Hydrogasification in the 4-Inch PDU

2-1

2.0.1

Product Gas Composition and Trace Components

2-4

2.0.2

Char Compositions

2-5

2.0.3

Liquid Products

2-6

2.1

Introduction

2-7

2.2

Description of Hydrogasification Process Development Unit (PDU)

2-7

2.2.1

Design Features

2-7

2.2.2

Flow Sheet

2-8

2.2.3

Reactor Description

2-9

2.2.4

Operation Sequence

2-11

2.2.5

Equipment Modification and Addition Details

2-12

2.2.5.1

Reactor Tube

2-12

2.2.5.2

Reactor Furnace

2-13

2.2.5.3

Feed Gas Tube

2-14

2.2.5.4

Coal Feed Tube

2-15

2.2.5.5

Coal Feed and Discharge

2-16

2.2.5.6

Product Gas Offtake Line

2-17

2.2.5.7

Product Gas Sample Probes

2-17

2.2.5.8

Coal Feed Hopper and Residue Receiver

2-18

2.2.5.9

Differential Pressure Control System

2-18

2.2.5.10

Coal Bed Level Sensors

2-18

2.2.5.11

Temperature Sensing

2-19

2.2.5.12

Auxiliaries

2-19

2.2.6

Electrical Heat Input to Reactor

2-28

2.3

Hydrogasification Tests in Process Development Unit

2-29

2.3.1

Coal Feedstocks

2-29

2.3.2

Coal Particle Size

2-31

2.3.3

Results of Operations

2-31

2.3.3.1

Moving Bed Hydrogasification Tests

2-31

2.3.3.1.1

Pretreated Bituminous Coal Results

2-32

2.3.3.1.2

Coal Pretreatment

2-32

2.3.3.1.3

North Dakota Lignite Results

2-32

2.3.3.1.4

Two-Stage Simulation

2-33

2.3.3.1.5

Methane Formation

2-33

2.3.3.1.5.1

Equilibrium

2-33

2.3.3.1.5.2

Reaction Rate

2-36

2.3.3.2

Reaction Profile-Gas Sample Probes

2-39

2.3.3.3

Free-Fall Tests

2-42

2.3.3.4

Fluidized Bed Tests

2-45

2.3.3.4.1

Pittsburgh No. 8 Seam Bituminous Coal

2-46

2.3.3.4.2

Ohio No. 6 Seam Bituminous Coal

2-47

2.3.3.4.3

West Virginia No. 5 Block Seam Bituminous Coal

2-47

2.3.3.4.4

Pocahontas No. 4 Steam Low-Volatile Bituminous Coal

2-47

2.3.3.4.5

Illinois No. 6 Seam Bituminous Coal

2-47

2.3.3.4.6

Indiana No. 6 Seam Bituminous Coal

2-47

2.3.3.4.7

West Virginia Sewell Seam Low-Volatile Bituminous Coal

2-48

2.3.3.4.8

Colorado Laramie No. 3 Seam Subbituminous Coal

2-48

2.3.3.4.9

North Dakota Lignite

2-49

2.3.3.4.10

Montana Subituminous Coal

2-50

2.3.3.4.11

Montana Lignite

2-50

2.3.3.4.12

FMC Corporation Project COED Char

2-53

2.3.3.4.13

West Virginia Medium-Volatile Content Bituminous Coal

2-55

2.3.3.4.14

New Mexico Subbituminous Coal

2-55

2.3.3.5

Effect if Synthesis Gas on Coal Gasification

2-58

2.3.3.6

1500-psig Hydrogasification Tests

2-65

2.3.3.7

500-psig Hydrogasification Tests

2-68

2.3.3.8

Product Gas Composition and Trace Components

2-73

2.3.3.9

Char Compositions

2-75

2.3.3.10

Liquid Products

2-75

Part 3

Appendix a-A:  4-inch Hydrogasification Data 4-inch Hydrogasification Data

A-1