|
3.0 |
Summary of Pilot Plant Development |
3-1 |
|
3.1 |
Introduction |
3-4 |
|
3.2 |
Hygas Process Considerations |
3-5 |
|
3.3 |
Preliminary Design: General |
3-7 |
| |
3.3.1 |
Raw Coal Handling |
3-8 |
|
3.3.2 |
Coal and Char Pretreatment |
3-8 |
|
3.3.3 |
Hydrogasification Section |
3-9 |
|
3.3.4 |
Purification Section |
3-10 |
|
3.3.5 |
Methanation |
3-11 |
|
3.4 |
Design Elaboration |
3-12 |
| |
3.4.1 |
Coal Pretreatment Section |
3-13 |
| |
3.4.1.1 |
Basis for Design |
3-13 |
|
3.4.1.2 |
Pretreater Reactor |
3-13 |
|
3.4.1.3 |
Pretreater Internal Solids Separators (2-T-4) |
3-17 |
|
3.4.1.4 |
Pretreater Cooling Coils (2-E-3) |
3-17 |
|
3.4.1.5 |
Pretreater Air Heater (2-F-1) |
3-17 |
|
3.4.1.6 |
Pretreater Combustion Air Compressor (2-K-1) |
3-17 |
|
3.4.1.7 |
Pretreated Char Cooler (2-T-5) |
3-18 |
|
3.4.1.8 |
Pretreater Quench System |
3-18 |
|
3.4.1.9 |
Pretreater Quench Tower (2-C-2) |
3-18 |
|
3.4.1.10 |
Quench Separators (2-C-3) |
3-18 |
|
3.4.1.11 |
Quench Cooler (2-E-1) |
3-19 |
|
3.4.1.12 |
Quench Circulation Pump (2-G-1) |
3-19 |
|
3.4.2 |
Hydrogasification Section |
3-20 |
| |
3.4.2.1 |
Basis for Design |
3-20 |
|
3.4.2.2 |
Hydrogasifier Process Flow |
3-20 |
|
3.4.2.3 |
Coal Feed |
3-29 |
|
3.4.2.4 |
Reaction System Vessel |
3-31 |
| |
3.4.2.4.1 |
Refractory Considerations |
3-31 |
|
3.4.2.4.2 |
Reactor Vessel Design |
3-32 |
|
3.4.2.4.3 |
Reaction System Vessel Layout |
3-32 |
|
3.4.2.5 |
Product Char Removal System |
3-34 |
|
3.4.2.6 |
Reactor System Control |
3-34 |
|
3.4.2.7 |
Solids Flow Control Valves |
3-36 |
|
3.4.3 |
Purification Section |
3-39 |
| |
3.4.3.1 |
Scope |
3-39 |
|
3.4.3.2 |
Hydrogasifier Effluent Quench System |
3-48 |
| |
3.4.3.2.1 |
Basis for Design |
3-48 |
|
3.4.3.2.2 |
Hydrogasifier Effluent Quench Tower (4-C-1) |
3-49 |
|
3.4.3.2.3 |
Quench Water Circulation Pumps (40C-1, 1B) |
3-49 |
|
3.4.3.2.4 |
Quench Separator (4-C-2) |
3-49 |
|
3.4.3.2.5 |
Quench Water Cooler (4-E-1) |
3-50 |
|
3.4.3.3 |
CO2 and H2S Removal System |
3-50 |
| |
3.4.3.3.1 |
Basis for Design |
3-50 |
|
3.4.3.3.2 |
CO2 and H2S Absorber (4-C-3) |
3-50 |
|
3.4.3.3.3 |
Regenerator (4-C-4) |
3-51 |
|
3.4.3.3.4 |
Lean Solution Pump (4-G-2) |
3-51 |
|
3.4.3.3.5 |
Amine Filter (4-T-1) |
3-52 |
|
3.4.3.3.6 |
Lean Solution Cooler (4-E-2) |
3-52 |
|
3.4.3.3.7 |
Lean-rich Solution Exchanger (4-E-3) |
3-52 |
|
3.4.3.3.8 |
Regenerator Refuels Condenser (4-E-5) |
3-53 |
|
3.4.3.3.9 |
Regenerator Reboiler (4-E-6) |
3-53 |
|
3.4.3.3.10 |
MEA-DEA Reclaimer ($E-4) |
3-53 |
|
3.4.3.4 |
Caustic and Water Wash Scrubber System |
3-54 |
| |
3.4.3.4.1 |
Basis for Design |
3-54 |
|
3.4.3.4.2 |
Caustic and Water Wash Column (4-C-5) |
3-54 |
|
3.4.3.4.3 |
Caustic Circulation Pump (4-G-3) |
3-54 |
|
3.4.3.4.4 |
Caustic Injection Pump (4-G-4) |
3-55 |
|
3.4.4 |
Methanation Section |
3-55 |
| |
3.4.4.1 |
Basis for Design |
3-55 |
|
3.4.4.2 |
Methanators (5-C-1 and 5-C-2) |
3-63 |
|
3.4.4.3 |
Methanator Feed-Effluent Exchanger (5-E-2) |
3-63 |
|
3.4.4.4 |
Methanator Effluent Air Cooler (5-E-3) |
3-63 |
|
3.4.4.5 |
Methanator Start-Up Heater (5-F-1) |
3-64 |
|
3.4.4.6 |
Methanator Recycle Compressor (5-K-1) |
3-65 |
|
3.4.5 |
General |
3-65 |
|
3.5 |
Start-Up and Initial Test of the Hygas Pilot
Plant |
3-65 |
| |
3.5.1 |
Introduction |
3-65 |
|
3.5.2 |
Equipment Commissioning |
3-65 |
|
3.5.3 |
Early Coal Preparation Tests |
3-78 |
|
3.5.4 |
Hydrogasifier Heat-Up |
3-78 |
|
3.5.5 |
Gasification Test No. 1, October 1971 |
3-79 |
|
3.5.6 |
Gasification Test No. 2, December 1971 |
3-81 |
|
3.5.7 |
Gasification Test No. 3, January 1972 |
3-84 |
|
3.5.8 |
Gasification Test No. 4, February 1972 |
3-86 |
|
3.5.9 |
Gasification Test No. 5, April 1972 |
3-93 |
|
3.5.10 |
Gasification Test No. 6, June 1972 |
3-95 |
|
3.5.11 |
Annual Plant Turnaround, July 1972 |
3-102 |
|
3.5.12 |
Gasification Test No. 7, August 1972 |
3-103 |
| |
| Appendix 3-A |
Materials and Corrosion Considerations |
| |
|
4.0 |
Summary of Hydrogen Generation |
4-1 |
| |
4.0.1 |
Hydrogasifier Reactor |
4-2 |
|
4.0.2 |
Gas Purification |
4-3 |
|
4.0.3 |
Methanation |
4-4 |
|
4.0.4 |
Hydrogen for the HYGAS Process |
4-4 |
| |
4.0.4.1 |
Electrothermal / 300 kW (6-Inch) Unit |
4-6 |
|
4.0.4.2 |
Electrothermal / 2.25 MW (30-Inch) Unit |
4-6 |
|
4.0.4.3 |
Steam-Oxygen Gasification |
4-7 |
|
4.0.4.4 |
Steam-Iron Gasification |
4-10 |
|
4.0.5 |
References Cited |
4-13 |
