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Return to DOE Reports Table of Contents - F Crow Tribe of Indians: Synfuels Feasibility Study Table of Contents Crow Tribe of Indians - Process Design and Cost Estimate Book I, Sections 1.0 through 6.2. Synfuels Feasibility Study - August 1982. Fluor Engineers and Constructors Department of Energy Table of Contents 1.0 Feasibility Study Overview 1-1 2.0 Introduction 2-1 3.0 Summary 3-1 3.1 Design Considerations 3-1 3.2 Base Case 3-3 3.3 Comparisons 3-4 3.3.1 Coal Feed Comparison 3-4 3.3.2 Product and Byproduct Summary 3-7 3.3.3 Capital Cost Summary 3-7 3.3.4 Operation and Cost Summary 3-11 4.0 Scope of Work 4-1 4.1 Process Development 4-1 4.2 Utility Systems Development 4-3 4.3 Offsites Development 4-4 4.4 Special Process Study 4-5 4.5 Capital and Operating Costs 4-5 5.0 Criteria, Rationale, and Assumptions 5-1 5.1 Coal Analyses 5-1 5.2 Site Data 5-5 5.2.1 Area Description 5-5 5.2.2 Sites Studied 5-5 5.2.3 Topographic Maps and Aerial Photographs 5-7 5.2.4 Site Reconnaissance 5-10 5.2.5 Meteorological and Design Data 5-10 5.2.6 Building Codes and Regulations 5-16 5.2.7 Description of Site 1 5-17 5.2.8 Description of Site 23 5-26 5.3 Raw Water Analysis 5-38 5.4 Utility Design Information 5-38 5.5 Product and Byproducts Specifications 5-40 5.5.1 Product Specifications 5-40 5.5.2 Byproducts and Ash Specifications 5-40 5.6 Economic Criteria – Capital Costs 5-42 5.6.1 Direct Field Cost Estimate 5-57 5.6.2 Indirect Field Cost Estimate 5-61 5.6.3 Office Cost Estimate 5-63 5.6.4 Material Transportation Cost Estimate 5-63 5.6.5 Other Capital Costs 5-64 5.6.6 Manpower Plans 5-70 5.7 Economic Criteria – Operating and Maintenance Costs 5-71 5.7.1 Coal Cost 5-71 5.7.2 Catalysts and Chemicals 5-71 5.7.3 Plant Management Staff 5-71 5.7.4 Plant Operating Labor and Materials 5-72 5.7.5 Maintenance Labor and Materials 5-72 5.7.6 Water Pumping Costs 5-72 5.7.7 Solid Waste Disposal 5-73 5.7.8 Taxes and Insurance 5-73 5.7.9 Byproducts Credit 5-73 6.0 Contents and Results 6-1 6.1 Base Case Overall Plant Description 6-1 6.1.1 Introduction 6-1 6.1.2 Feed and Product Summary 6-5 6.1.3 Thermal Efficiency Calculation 6-8 6.1.4 Design Basis 6-10 6.1.5 Plant Units 6-17 6.1.6 Plant Train Philosophy 6-20 6.1.7 Plot Plan 6-28 6.1.8 Block Flow Diagrams 6-31 Overall Material Balance 6-31 Plant Water Balance 6-31 Sulfur Balance 6-35 Air Emissions 6-37 Solid Effluents 6-37 Steam Balance 6-40 6.1.9 Utility Summary 6-42 6.1.10 Catalyst and Chemicals Summary 6-44 6.1.11 Operating Manpower 6-51 6.1.12 Maintenance Manpower 6-53 6.2 Base Case Process Units – Engineering Data 6-54 6.2.1 Unit 1 – Coal Screening 6-54 6.2.2 Unit 2 – Coal Distribution 6-62 6.2.3 Unit 3 – Ash Handling 6-68 6.2.4 Unit 10 – Coal Gasification 6-77 6.2.5 Unit 11 – Carbon Monoxide Shift 6-87 6.2.6 Unit 12 – Gas Cooling 6-94 6.2.7 Unit 13 – Rectisol 6-101 6.2.8 Unit 14 – Gas Liquor Separation 6-112 6.2.9 Unit 15 – Tar Distillation 6-121 6.2.10 Unit 16 – Naphtha Hydrotreating 6-128 6.2.11 Unit 17 – Phenosolvan 6-137 6.2.12 Unit 18 – Ammonia Recovery 6-147 6.2.13 Unit 19 – Sulfur Recovery 6-155 6.2.14 Unit 20 – Process Steam Superheating 6-177 6.2.15 Unit 21 – Methanol Synthesis 6-183 6.2.16 Unit 22 – Methanation 6-190 6.2.17 Unit 23 – SNG Purification and Compression 6-200 6.2.18 Unit 24 – Partial Oxidation 6-207 6.2.19 Unit 25 – PSA Hydrogen Production 6-215 | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||