Part 1, Sec 1 - 3.8,  4.61 MB

1.0

Introduction

1-1

1.1

Project Background

1-1

1.2

Project Overview

1-4

1.3

Approach to Definitive Design

1-4

1.3.1

Market and Fuel Use Considerations

1-5

1.3.2

Site Considerations

1-7

1.3.3

Coal Considerations

1-10

1.3.4

Process Considerations

1-11

1.3.5

Criteria for Definitive Design

1-13

2.0

Basis for Process Design

2-1

2.1

Plant Site

2-1

2.2

Plant Site

2-1

2.3

Coal Feed

2-3

2.4

Gasification Process

2-3

2.5

Sulfur Removal and Recovery

2-4

2.6

Makeup Water Supply

2-4

2.7

Solid Waste Disposal

2-5

3.0

Process Description

3-1

3.1

Overall Process Description

3-1

3.2

Coal Receiving and Handling

3-13

3.2.1

Coal Receiving

3-13

3.2.2

Conveying to Storage, Weighing, and Sampling

3-14

3.2.3

Coal Storage

3-15

3.3

Coal Preparation and Conveying

3-15

3.4

GKT coal gasification and wash water treatment

3-17

3.5

Sulfur Removal and recovery

3-27

3.5.1

Stretford Desulfurization

3-27

3.5.2

Nittetu Incineration

3-32

3.6

Air Separation

3-33

3.7

Product Gas Handling

3-39

3.7.1

Gas Compression

3-39

3.7.2

Gas Dehydration

3-40

3.8

Wastewater Treatment

3-42

Part 2, Sec 3.9 - 4.3.7, 4.52 MB

3.9

Utility Support Systems

3-44

3.9.1

Plant and Potable Water System

3-44

3.9.2

Cooling Water System – Process Plant

3-45

3.9.4

Other Plant Utility Support Systems

3-49

3.9.5

Plant Offsite Support Systems

3-51

3.10

Labor, Raw Materials, and Utility Requirements

3-55

4.0

Plant Design

4-1

4.1

Plant Description

4-1

4.1.1

Risk Assessment

4-2

4.1.2

Operational Considerations

4-5

4.2

Site Work

4-5

4.2.1

Site Preparation

4-5

4.2.2

Structural Design

4-6

4.3

Process Equipment

4-8

4.3.1

Coal Receiving and Handling

4-8

4.3.2

Coal Preparation and Conveying

4-18

4.3.3

GKT Coal Gasification Facility

4-25

4.3.4

Sulfur Removal and Recovery

4-34

4.3.5

Air Separation Facility

4-42

4.3.6

Gas Compression and Dehydration

4-45

4.3.7

Wastewater Treatment

4-54

Part 3, Sec 4.3.8 - 5.3.2, 3.61 MB

4.3.8

Utilities and Supporting Systems

4-60

4.4

Plant Electrical Design

4-89

4.4.1

Plant Electrical Design Criteria

4-89

4.4.2

Plant Electrical System

4-90

4.4.3

Plant Short Circuit Levels

4-91

4.4.4

Plant Power System Operation

4-92

4.4.5

Plant Motors and Motors Control

4-97

4.4.6

Plant Instrument and Control Systems

4-98

4.4.7

Plant Lighting

4-109

4.4.8

Plant Communication Systems

4-109

4.4.9

Plant Fire Protection system

4-110

4.4.10

Plant CO Monitoring System

4-111

4.4.11

Plant Security System

4-111

4.4.12

Determination of Annual Electrical Usage

4-111

4.5

Gas Distribution System

4-112

4.5.1

Design Basis

4-112

4.5.2

Design Approach

4-115

4.5.3

Sample Calculation

4-117

4.5.4

Design Description

4-118

5.0

Alternate Operating Scenarios

5-1

5.1

Purchase of Oxygen

5-1

5.2

Coal via the Port Richmond Terminal

5-2

5.3

CO Generation for Loading Leveling

5-3

5.3.1

Capital Costs

5-6

5.3.2

Operating Costs

5-6

 Appendices

App. A - E,  5.69 MB 

A

Coal Search

246

B

Fly Ash Recycle

267

C

Stretford Plant Sulfur Recovery Options

272

D

Layout Drawings

288

E

Piping Flow Diagrams

309

App. F - G,  3.41 MB

F

Electrical Drawings

336

G

Instrument and Control Logic Diagrams

351

App. H - I, 4.20 MB

H

Master Instrument Index

406

I

PGW Conceptual Plant Design Review

454

App. I-4 - K, 4.70 MB

J

Equipment List

532

K

Motor List Used for Total Plant Load Calculation

581