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EXXON Catalytic Coal Gasification Process: Predevelopment Program Table of Contents

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

T. Kalina
N. C. Nahas

EXXON Research and Engineering Co.

Table of Contents (759kb)

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