EXXON Catalytic Coal Gasification Process: Predevelopment Program. Final Project Report

EXXON Catalytic Coal Gasification Process: Predevelopment Program.
Final Project Report - 1978

Abstract				v
List of Tables				vi
List of Figures				viii
Introduction and Summary				x

1	Fluid Bed Gasifier (FBG) Studies (1.55MB)			1
	1.1	FBG Recommissioning		1
		1.1.1	Mechanical Modifications	1
		1.1.2	Updating of On-Line Data Acquisition System	4
	1.2	FBG Operations		6
		1.2.1	Startup and Baseline Operations	7
		1.2.2	Process Variable Studies	9
		1.2.3	Catalyst Recycle Operations	10
		1.2.4	Char Production Operations	12
	1.3	FBG Data Analysis		12
		1.3.1	Initial Operations	16
		1.3.2	Process Variable Studies with K₂CO₃ Catalyst	17
		1.3.3	Mixed Catalyst Operations	18
		1.3.4	Catalyst Recovery Operations	19
		1.3.5	Char Production Operations	19
		1.3.6	Comparison of FBG Data with Reactor Model Predictions	19
	1.4	Catalyst Recycle Operations		22
		1.4.1	Operations of the Catalyst Recovery Unit (CRU)	22
		1.4.2	Overall Catalyst Recycle Loop Operations	22
	1.5	Pilot Scale Secondary Catalyst Recovery		26
	1.6	FBG Scrubber Water Analysis		28
2	Bench Scale Studies (2.38MB)			31
	2.1	Continuous Gasification Unit (CGU) Operations		31
		2.1.1	CGU Operating Experience	31
		2.1.2	CGU Data Analysis	35
	2.2	Fixed Bed Gasification Reaction Studies		39
		2.2.1	Experimental Apparatus and Procedure	39
		2.2.2	Kinetic Data Interpretation	43
		2.2.3	Generalized Fixed Bed Model	51
		2.2.4	Alternate Catalyst Systems	54
	2.3	Recovery of Water Soluble Catalyst		62
		2.3.1	Chemical Forms of Water Soluble Potassium	62
		2.3.2	Improvement of Catalyst Recovery from the CRU	66
	2.4	Recovery of Water Insoluble Catalyst		73
		2.4.1	Mineral Matter Reactions	75
		2.4.2	Experimental Procedure	76
		2.4.3	Effect of Washing Solutions	76
		2.4.4	Effects of Temperature, Residence Time, and Calcium Loading	81
		2.4.5	Catalyst Recovery from Combusted Char	83
		2.4.6	Data Analysis	84
	2.5	Catalyst Recovery via the Formate Process		85
3	Engineering Research and Development (1.73MB)			88
	3.1	Catalyst Source/Recovery Studies		89
		3.1.1	Commercial Sources of Potassium and Sodium Catalyst	89
		3.1.2	"Cash Flow" Analysis of Alternative Catalyst Manufacturing Process	92
		3.1.3	Screening Evaluation of the Engel-Precht Process	95
		3.1.4	Screening Evaluation of Alternative Electrolysis Technologies	96
		3.1.5	"Cash Flow" Analysis of Alternative Catalyst Recovery Processes	98
		3.1.6	Screening Study of Ca(OH)₂ Digestion	101
	3.2	Gasification Reactor System Studies		104
		3.2.1	Evaluation of the Incentive for Secondary Gasification	104
		3.2.2	Evaluation of Two-Stage Gasifier with Upper Drying Stage	109
		3.2.3	Impacts of Catalyst Gasifier Operating Conditions	114
	3.3	Acid Gas Removal Studies		118
		3.3.1	Evaluation of Conventional Acid Gas Removal Process	118
		3.3.2	Evaluation of Cryogenic Fractionation for Acid Gas Removal	119
4	Commercial Plant Study Design and Economics (2.05MB)			121
	4.1	Study Design Steps and Depth of Engineering Detail		122
	4.2	Project Basis		124
	4.3	Process Basis		125
		4.3.1	Coal Drying and Catalyst Addition	125
		4.3.2	Reactor System	125
		4.3.3	Product Gas Cooling and Scrubbing	130
		4.3.4	Sour Water Stripping and Ammonia Recovery	130
		4.3.5	Acid Gas Removal and Sulfur Recovery	130
		4.3.6	Methane Recovery System	130
		4.3.7	Refrigeration	131
		4.3.8	Catalyst Recovery	131
	4.4	Detailed Material and Energy Balances		132
	4.5	Equipment Design for Onsites		132
		4.5.1	Section 100 - Coal Drying and Catalyst Addition	132
		4.5.2	Section 200 - Reactor System	135
		4.5.3	Section 300 - Product Gas Cooling and Scrubbing	137
		4.5.4	Section 400 - Sour Water Stripping and Ammonia Recovery	137
		4.5.5	Section 500 - Acid Gas Removal and Sulfur Recovery	138
		4.5.6	Section 600 - Methane Recovery System	139
		4.5.7	Section 700 - Refrigeration	139
		4.5.8	Section 800 - Catalyst Recovery	139
	4.6	Overall Plant Utilities Balances		140
	4.7	Equipment Sizing for Offsites		142
	4.8	Plant Investment		144
		4.8.1	Investment Cost Estimating Approach	144
		4.8.2	Investment for a Pioneer Commercial Plant	145
	4.9	Economics		147
		4.9.1	Basis for Calculation of SNG Cost	147
		4.9.2	SNG Cost for a Pioneer Commercial Plant	149

APPENDIX A - FLUID BED GASIFIER YIELD PERIOD DATA (5.67MB)				153
	A.1	Yield Period 202		156
	A.2	Yield Period 203		164
	A.3	Yield Period 204		173
	A.4	Yield Period 205		180
	A.5	Yield Period 206		188
	A.6	Yield Period 207		196
	A.7	Yield Period 208		204
	A.8	Yield Period 209		212
	A.9	Yield Period 210		220
	A.10	Yield Period 211		228
	A.11	Yield Period 212		236
	A.12	Yield Period 213		244
	A.13	Yield Period 214		252
	A.14	Yield Period 215		260
	A.15	Yield Period 216		268
	A.16	Yield Period 217		276
	A.17	Yield Period 218		284
	A.18	Yield Period 219		292

APPENDIX B - PUBLICATIONS (2.81MB)				300
	B.1	Catalytic Gasification Predevelopment Research		301
	B.2	Kinetics of Potassium Catalyzed Gasification		307
	B.3	Catalytic Coal Gasification Process Research and Development		327
	B.4	Production of SNG from Illinois Coal via Catalytic Gasification		336