| Section I. Introduction |
1 |
| Overall Project Objective |
1 |
| Methanation Processes |
3 |
| Direct Methanation Process Advantages |
5 |
| Description of Improved Process |
5 |
| |
Process Option A |
7 |
| Process Option B |
8 |
| Process Option C |
8 |
| Definition of Terms |
9 |
| |
| Section II. Work Plan |
11 |
| Task I. Establishment of Consistency of
Catalyst performance |
11 |
| Task II. Measurement of the Effect of
Temperature, Pressure, and Feed Composition on the Methanation
Reaction |
12 |
| Task III. Measurement of the Effect of
Space Velocity on Conversion |
12 |
| Task IV. Measurement of the Effect of H2/CO
Molar Ratio and H2O on Conversion |
12 |
| Task V. Measurement of the Effect of
Benzene, Phenol, and Ammonia on Conversion |
12 |
| Task VI. Measurement of the Effect of
Carbon Dioxide on Conversion |
12 |
| Task VII. Reporting |
12 |
| Task VIII. Technical Services |
12 |
| Task IX. Obtain Design Data |
12 |
| Task X. Design, Construct, and Operate
an Adiabatic Reactor System |
13 |
| Task XI. Obtain Adiabatic Design Data |
13 |
| Task XII. Test Direct Methanation
Catalysts |
13 |
| Task XIII. Determine Catalyst Life |
13 |
| Task XIV. Determine Kinetics of
Reaction(s) |
14 |
| Task XV. Support Process Development |
14 |
| Task XIV. Provide Storage of Chemical
By-Products Derived from the Gasification of Illinois Basin Coal by
the Lurgi Process |
14 |
| |
| Section III. Evaluation of GRI-C-284
Catalyst |
15 |
| Study of the Effect of Sulfurs on the
Activity of the Catalyst |
15 |
| Study of the Effect of Temperature,
Pressure, and Composition on the Activity of the Catalyst |
15 |
| Study of the Effect of Steam on the
Activity of the Catalyst |
16 |
| Study of the Effect of Hydrogen/Carbon
Monoxide Ratio on the Activity of the Catalyst |
16 |
| Study of the Effect of Benzene and
Phenol on the Activity of the Catalyst |
17 |
| |
| Section IV. Evaluation of Union Carbide
CRL-T-1 Catalyst |
19 |
| |
| Section V. Evaluation of GRI-C-318
Catalyst |
23 |
| |
| Section VI. Evaluation of Shell Chemical
Co. CB 79-57 Catalyst |
25 |
| |
| Section VII. Evaluation of GRI-C-486
Catalyst |
27 |
| |
| Section VIII. Evaluation of MC-100
Catalyst |
29 |
| |
| Section IX. Evaluation of G-93 Catalyst |
31 |
| |
| Section X. Evaluation of LB 121479L
(GRI-C-525, GRI-C-528, GRI-C-529) Catalysts |
33 |
| Determination of catalyst Bulk Density |
33 |
| |
| Section XI. Evaluation of GRI-C-V
Catalyst |
35 |
| |
| Section XII. Evaluation of GRI-C-600
Catalyst |
37 |
| |
| Section XIII. Evaluation of GRI-C-700
Series Catalysts |
39 |
| Effect of Low Sulfur Concentration |
40 |
| |
| Section XIV. Evaluation of GRI-C-800A
and GRI-C-800B Catalysts |
41 |
| Additional Design Data for the Direct
Methanation/Lurgi Process |
42 |
| |
| Section XV. First-Cut Design Data for
the Direct Methanation Process Using a British Gas Corporation
Slagging Gasification-Type Raw Gas (BGC/Lurgi Slagger) |
43 |
| Preconditioning BGC Slagger-Type Raw Gas
to Adjust the H2/CO Ration |
43 |
| Obtaining Design Data for Each
Methanation Stage |
44 |
| Evaluation of GRI-C-525 Catalyst for
High-Temperature Resistance |
47 |
| |
| Section XVI. First-Cut design Data for
the Direct Methanation Process Using a Westinghouse
Gasification-Type Raw Gas |
49 |
| |
| Section XVII. First-Cut Design Data for
the Direct Methanation Process Using a Dry-Bottom Lurgi-Type Raw Gas |
51 |
| Evaluation of Alternative Options for
the Direct Methanation Process |
53 |
| |
| Section XVIII. First-Cut Design Data for
the Direct Methanation Process using an underground Coal
Gasification-Type Raw Gas (UCG) |
55 |
| Direct Methanation Process Scheme I |
56 |
| Direct Methanation Process Scheme II |
56 |
| Direct Methanation Process Scheme III |
57 |
| Experimental Results |
57 |
| Direct Data for the Direct Methanation/Shell
Process |
59 |
| |
| Section XIX. Design Data for the Direct
Methanation/Shell Process |
59 |
| |
| Section XX. Life Tests of the GRI-C-525
and GRI-C-600 Catalysts |
61 |
| Reactor System |
61 |
| Test Conditions |
61 |
| Effect of Metal Carbonyls on the Life
and Activity of Catalysts |
66 |
| 2000-Hour Life Test of the GRI-C-500 and
the GRI-C-600 Catalysts |
68 |
| Measured Effects of Process Conditions
on CO Conversion and CH4 Selectivity |
70 |
| The Fate of Ethane, Ethylene, Propane,
and Butanes |
72 |
| |
| Section XXI. COS Hydrolysis and
Hydrogenation Reactions |
73 |
| |
| Section XXII. Steam Reforming of a
Sulfur-Containing Natural Gas |
77 |
| |
| Section XXIII. Major Accomplishments |
79 |
| |
| Section XXIV. Major Technical Problems
Encountered |
83 |
| |
| Section XXV. Conclusions and Significant
Findings |
85 |
| |
| Section XXVI. Acknowledgement |
87 |
