Evaluation of Pollution Control in Fossil Fuel Conversion Process, Final Report

Evaluation of Pollution Control in Fossil Fuel Conversion Process.
Final Report - 1976

Acknowledgements
1	Introduction (337kb)				1
	1.1	Background			1
	1.2	Literature survey			2
		1.1.1	Trace Elements in Fossil Fuels		2
		1.1.2	Coal and Crude Oil Conversion/Treatment Processes		2
	1.3	Discussion with Process Developers			3
	1.4	Trips to Commercial Plants			3
	1.5	Preliminary Process Designs			3
	1.6	Analytical Test Plan			4
	1.7	Transient Pollutants			4
2	Coal Gasification Plants (2.12MB)				7
	2.1	General Gasification Description			7
	2.2	Coal Storage and Preparation			11
		2.2.1	Description of Coal Storage and Preparation		11
		2.2.2	Effluents to Air from Coal Storage and Preparation		14
		2.2.3	Liquids and Solids Effluents from Coal Storage and Preparations		15
		2.2.4	Process Alternatives		15
	2.3	Gasification and Quench Sections			16
		2.3.1	Gasifiers and Operating Conditions		16
		2.3.2	Gasifier Effluents to Air		18
		2.3.3	Liquid and Solid Effluents		18
		2.3.4	Process Alternatives		18
	2.4	Shift Conversion and Cooling			23
		2.4.1	Description of Shift Conversion		23
		2.4.2	Effluents to Air from shift Conversion and Cooling		23
		2.4.3	Liquids and Solid Effluents from Shift Conversion and Cooling		24
		2.4.4	Process Alternatives in Shift Conversion and Cooling		24
	2.5	Acid Gas Removal			24
		2.5.1	Description of Acid Gas Removal		24
		2.5.2	Effluents to Air From Acid Gas Removal		28
		2.5.3	Liquids and Solid Effluents from Acid Gas Removal		28
		2.5.4	Process Alternatives in Acid Gas Removal		28
	2.6	Methanation Section			29
		2.6.1	Description of the Methanation Section		29
		2.6.2	Effluents to Air from the Methanation Section		30
		2.6.3	Liquids and Solid Effluents		30
		2.6.4	Process Alternatives in Methanation		30
	2.7	Compression and Drying			30
	2.8	Final Product and Gas			31
	2.9	Oxygen Plants			31
	2.10	Sulfur Recovery			31
		2.10.1	Description of Sulfur recovery		31
		2.10.3	Effluents from Sulfur Recovery		34
	2.11	Ash and Solids Disposal			36
		2.11.1	Description of Ash and Solids Disposal		36
		2.11.2	Effluents to Air from Solids Disposal		36
		2.11.3	Liquids and Solids Effluent from Solids Disposal		36
		2.11.4	Process Alternatives in Solids Disposal		38
	2.12	Wastewater Treatment			38
	2.13	Power and Steam Generation			43
		2.13.1	Alternatives in Power and Steam Generation		43
		2.13.2	Effluents from Power and Steam Generation		45
	2.14	Cooling Water System			45
	2.15	Raw Water Treatment			48
	2.16	Miscellaneous Plant Sections			48
		2.16.1	CO₂ Acceptor Regeneration		48
		2.16.2	Low BTU Fuel Gas Production in the Lurgi Process		48
		2.16.3	Low BTU Fuel Gas Production in the HYGAS Process		51
3	Coal Liquefaction Plants (926kb)				55
	3.1	General Description of Coal Liquefaction Plants			55
	3.2	Main Liquefaction Train			57
		3.2.1	Coal Storage and Preparation		57
		3.2.2	Coal Liquefaction		57
		3.2.3	Products Separation		64
		3.2.4	Hydrotreating		64
	3.3	Hydrogen Production			64
	3.4	Auxiliary Facilities			68
		3.4.1	Oxygen Plants		68
		3.4.2	Acid Gas Removal		68
		3.4.3	Sulfur Recovery		72
		3.4.4	Ash and Solids Disposal		72
		3.4.5	Wastewater Treatment		72
		3.4.6	Electricity and Steam Generation		72
		3.4.7	Cooling Water System		77
		3.4.8	Raw Water treatment		77
4	Coal Treating (114kb)				87
	4.1	Description of the Meyers Process			87
	4.2	Feed, Products, Utilities and Effluents of the Meyers Process			87
5	Thermal Efficiency (356kb)				92
	5.1	General			92
	5.2	Non-Process Related Factors Affecting Thermal Efficiency			92
	5.3	Thermal Efficiencies of Processes Investigates			94
	5.4	Detailed Losses in Thermal Efficiency			94
6	Stream Analysis for Trace Elements and Other Potential Pollutants (1.24MB)				99
	6.1	General			99
	6.2	The Fate of Trace Elements in Coal Conversion			99
		6.2.1	Trace Elements in Coals		99
		6.2.2	Trace Elements in Coal Feed to Processes in this Study		105
		6.2.3	Fate of Trace Elements in Coal		105
	6.3	Trace Elements in Petroleum and Shale			108
		6.3.1	Correlations Indicated		108
		6.3.2	New Data Required		109
	6.4	Trace Compounds Formed in Coal Conversion			109
	6.5	Data Acquisition			113
		6.5.1	Analyses to be made		113
		6.5.2	Analytical Techniques		113
		6.5.3	Coal Conversion Streams to be sampled		113
	6.6	Analysis of Streams from Commercial and Development Scale Gasification Plants			121
7	Technology Needs (251kb)				133
	7.1	Trace Elements in Coal			133
	7.2	Trace Elements and Other Potential Pollutants in Coal Conversion			134
	7.3	Improvements in Thermal Efficiency			135
8	Transient Pollutants (2.51MB)				137
	8.1	General			137
	8.2	Startup			138
	8.3	Shutdown			143
	8.4	Upsets			153
		8.4.1	General		153
		8.4.2	Coal Storage and Preparation		154
		8.4.3	Crushing and Screening		155
		8.4.4	Drying		155
		8.4.5	Pretreatment		156
		8.4.6	Coal Conversion		158
			8.4.6.1	Gasification	158
			8.4.6.2	Liquefaction	160
		8.4.7	Shift and Cooling		162
		8.4.8	Acid Gas Removal		163
		8.4.9	Methanation, Compression and Drying		164
		8.4.10	Sulfur Plant		165
		8.4.11	Oxygen Plant		166
		8.4.12	Solids Disposal		167
		8.4.13	Water Treatment		167
		8.4.14	Steam and Power Supply		172
	8.5	Maintenance			174
	8.6	Chemicals and Catalyst Replacement			175
	8.7	Storage of Products and Byproducts			176
	8.8	Design Considerations			176
9	Bibliography (353kb)				179
Appendices (5.65MB)