14759-T1, Vol 2, 14, Pages 122 - 236, 4.41 MB(material balance)

8/7/2019 14759-T1, Vol 2, 14, Pages 122 - 236, 4.41 MB(material balance)

1/115

,.

1 . 2 . 5 G A S X ~ X C A T X O N - U N I T 2 1

The Texaco Coal Ga si fi ca ti on Process (TCGP), chara ~teriz ed as anent rain ed s lagging downflow gas i f i er , i s u t i l iz ed iu the ~esi~n of theGasol ine Pla n t . The u t i l iz at i on of th is technology was spe ci f ied in theCooperative Agreement Statement of L~ork~ith engineering design informationobtained through Texaco Development Corporation.

A. Basis of Design

The qu an ti ty of synthesis gas generation capacity required bythe size of the Gasoline Plant ue,-.essitated th~ incorporation of 20 opeza~ingcoal gasl fler trains and two spares luto the design. The total of 22 trainsare arranged in four modul es wit, two mod ule s con tai nin g six train s (fiveoper ati ng plus on e spare ) and :he remai ning two ~odules contain five each.T h e f ee d a ~ d p r o d u c t s t r e a m s s h o w n o n t h e f o l l o w l n g t w o p a g e s d e p i c t t h edesign basis utilized in the d".siE~ of this unit.

B. _Process Sele ct io n Rat,io.al_~eThe des ign of the Gaeoll ne Plant centers around the TCGP for

combustion of Kentuc ky No. 9 high-sulfur, agglomerating coal speci fied in theCoo per at i ve Agreement. This commercial ly ava i la b le technology has beendemonstrated as capable of efficiently gas ify ing hlg h-s ulf ur conte nt, highs w e l l i n g i n d e x c o a l s ; o p e r a t l n 8 a t h l gh - pr e ss u re and affordin E an excellenth e a t r e c o v e r y s c h e m e to r e d uc e o p e r a t i n g c o s t ; a n d p r o d u c i n g a nenvironmenta lly acceptable sy nEas and nonhazardous slag.

I n th e e n s u i n g y ea r s , a c o m m e r c i a l l y s i z ed 8 Q m o n s t r a t i o npla nt has bee n bu ilt and s operating at the RuhrcheeL%e Chemlc~1 Complex inO'~erhausen-Holten, West Germany . The Ruh rch eml e gas lfl er has bee n runn ingsuc ces sfu lly since ear ly 1978. For these reason.s, Texaco has llcensed thisprocess foe other co~nercisl installations and co nsi der s this p roce ss to becommercial.

m m . e ~ i - - - - ,

w ~

~ - 1 . 2 . 5 - 1


2/115

ti

Component

GaslfJ.er F e e d S t r e a m s

inl

T o t a l C o a l S l u r r yt o C ~iflcation(Ib mol/hr)Total Oxygento Gasification(lb ~ol/hr)

C H 2coCO202N2

H2SCO S

T o t a l . D r y , " Ib m o . ~ /h rI {20T o t a l W e t , l b m o l / h rCoal, l b / h rAsh, Ib/l~C a r b o n

Total, lb/hrP E e ~ s u E e , p s l aT e m p e r a t u r e , F

P r o p r i e t a r y

P r o p r l e ~ a r y

1 ~ 2 0 02 0 0

m

i

5 4 , 9 6 8 . 7 6i

2 7 6 . 2 8m

5 5 , 2 4 5 . 0 4m

55,245.04

1 , 770~0401 , 0 1 5

2 0 0

~ l m m m m m m m w

( ,

I ~ - 1 . 2 . 5 - 2


3/115

i

Component

CH4C0CO202N2ArH2SCOSTotal Dry, lb mol/ tn"H 2 0Total Wet, ib mol/hr

Total., 1b/hePressure, psiaTemperature, F

Product Streamsm i i i

Total Raw Syngas(ib mol/hr) (molZ)i . i i m - , ~ J i m

62~580.97 36.19343.44 0.20

75,760.77 43.8130,788.72 17.81

m m823.02 0.48276.24 0.16

2,201.17 1.27135.71 0.08m

172,910.04 100.00123.170.76296,080.80

5 ,945 ,560 .00

874435

I I -1 .2 .5 -3 I


4/115

C . Process D esc r ip t i on

The equ ipmen t a r rangemen t and ma te r i a l ba l ance fo r . t h i s un i tare shown on Process Plo w and Control Diagr am D-21-MP-INP.

The coal -w ate r s lur ry i s . pumped a t h igh pressure through theslurry preheater into the gaslfler. Zn the gaslfler, the s lurr y is par tia llyo x i d i z e d w i t h o x y g e n a t 900 pslg and at hig h temperature. The hot synth esisE a s a nd m o l t e n s l a g g e n e r a t e d f l o w s d o w n w a r d f r o m th e g a s l f i e r i n t o t h eradia nt boiler, where much of the heat of reaction is recovered by generatingh l g h - p r e s s u r e s a t u r a t e d s t e a m . T h e s l a g f a l l s i n t o t h e w a t e r s u m p a n ds o l l d i f l e s a n d s h a t t e r 8 t o g l a s s - l l k e g r a n u le s . Th e s y n t he s i s ga s i swithdra wn from the radiant boi ler for further processing,

-..,

The gas ex i t i ng t he rad i an t w as t e hea t bo i l e r unde rgoes asuccession of scrubbing stages to remove part icu late mate rial . At the fina lstep, the gas is w~sh ed wit h condensate before it flows t o the CO Shift Unit.

A s u b s t a n t i a l p o r t i o n o f t h e a s h a nd r e c y c le s l a g i n t h eg a s l f i e r f e e d a g g l o m e r a t e s i n t o c o a r s e m o l t e n s l a g d r o p l e t s . T h e s l a g i ssolidified and quenched in the radiant boiler. This slag set tles thr oug h thewat er bath and is collected in a lock hopper. The contents of the lock hopperare discharged p e r i o d i c a l l y ,

The coars e s lag i s sen t to s l ag d ispo sal whi le water and s lagfin es pass ing through a screen are pumped to the c lar i f i ca t ion system.

W ate r s t ream s f rom the rad i an t bo i l e r , s l ag d i scha r ge , andthe sc rubbe r sy s t em con ta in su spended a sh and cha r pa r t i c l e s , w h ich a rerou t ed t o a c l a r i f i ca t i on sy s t em . The f i ne s l ag and unconver t ed coa l a reformed in a concen t ra t ed uuderf low that i s r e tur ned to the Coal Gri ndin g andSlu r r y Prepa ra t i on U n i t , The c l a r i f i~d w a te r ove r fl ow s i n to a w a te r ho ld ingt ank fo r reuse i n t he gas i f i ca t i on sy st em,

t

I I - 1 . 2 . 5 - 4


5/115

v . ' . o , , , , ,

C ,,

q

. . . . . . ~ - . j I I I I I

D. R i s k A s s e s s m e n t

The comme rcia l ly a vai l ab le Texaco Coal Gas i f i ca t ion Processof fe re d through Texaco Development Corpora tion (TDC) is an exp an sio n o f ~hewel l -p rov en Texaco Synt hes is Cas Generat ion Pro ces s. TDC, a whol ly ownedsub sid iar y of Texaco Inc . , has been engaged in the development and l ic en si ngof the Texaco Synehesis Gas Generation Process s~nce 1945. The synthesis gasg e n e r a t e d by t hi s t e c h n o l o g y l e a m i x t u r e p r e d o m i n a n t l y o f h y d r o g e n e n dc a r b o n m o a o x i d e ~ w h i c h i s u s e d a s a f e e d s t o c k f o r th e p ro d u c t io n o f a m m o n i a ,methanol, hydrogen; oxo products, reducing gas, fuel gas, and Yls ch er -T rop sc hl~quid hydrocarbons.

O v e r 8 0 T e x a c o s y n t h es i s g a s g e n e r a t i o n p l a nt s h a v e b e e nllcensed since the earl y 19508 ~nvolvln some 150 gasiflers, Early unit s w er en a t u r a l g a s - f l r e d . L a t e r , l i q u i d f u e l s s u c h a s n a p h t h a a nd h e s v y f u el o i lw e r e I n t r o d uc e d . T h e m a j o r i t y o f p l a n t s n o w in o p e r a e l o n u t i l i z e h e a v yresidual oils,

G ener a t o r s i ze has i nc r eased s t ead i l y , w i th p r e sen t un i t sproducing 20 t imes the outp ut of the ear l y commercia l uni t s . Oper a t in gpr es su re has ~se n from 350 psi~ in in it ia l plan ts to 1,200 ps~g in one plantiu ope ra tio n sin ce 1968. Commercial ope rati on as low as 30 psi~ has a ls o be endemo nst r a t ed . P i l o t uni t commercial ope ra t io u on r es i dual fue l s has beencondu cted a t 2,500 psiE, SynEas coo ler s have been used in 20 commercialpl an ts , ~hile the remainder have used dire ct quench.

The Texaco Coal Gasification Process s a modification of theTexaco Synthesis Cas Generation Process, producing generally the same type ofsyntheses gas for the same commercial applications. Developmeut work on coalgas i f i ca t ion , s t a r t ed in 1948, has involved l a rge - sca le p i lo t uni t opera t ionon many sol id fuels including l igu i tu s, bi tuminous coa ls, ant hra ci t es , coa l -l iquefact ion residues, and pet roleum cokes.

~'- - - - - -

. . . . : ~:~

11-1.2.5-5


6/115

~ g . .. .. .. .. ~ . . . . . . ~ p t l ~ t ~ g 0 p l ~ o J e ~ n ~ e u ~ P I ~

A d u m o n s t r a t l o n p l a n t w a s e r ec t e d a t t h e M o r g a n t o w n O r d n a n ceW o r ks i n W e s t V i r g i n i a i n 19 5 6. T h i s u n i t c h a r g e d I 0 0 t o n s p e r d a y o f a ne a s t e r n b i t u m i n o u s c o a l i n w a t e r s l u r r y a n d w a s i n o p e r a t i o n f o r 2 y e a r s.This piant confirmed gaslfler sca le- up cr~terla and dem ons tr ate d the ash-handling system,

A t t h e M o n t e b e l l o R e s e a r c h L a b o r a t o r y , e x t e n s i v e f a c i l i t i e s~re availa~l~ fc~ the gasification of solid fuels. These include thre e 15- to2 0 - t p d c o a l g a s i f i c a t i o n p i l o t u n i t s i n c l u di n g o n e s t a n d - a l o n e p i l o t p l an t .T e s t l n E h a s i n c l u d e d g a c o o li n g , s u l f u r r e m o v a l , a n d w a s t e w a t e r t r e a t m e n t .T h e s e p i l o t u n i t s h a v e b e e n o p e r a t i n g o n a w l d e r a n ge o f c o a l s s t p r e s s u r e sr a n~ i ng f r o m 3 0 0 t o 1 , 2 0 0 p s i . D e t a i l e d e n v i r o n m e n t d a t a h a v e b e e na c c u m u l a t e d o n b o t h e a s te r n a n d w e s t e r n U . S . c o a l.

R u h r c h e m i e A O ( RC H ) an d R u h r k o h l e A G ( R A G ) c o m p l e t e d ade mo ns tr at io n plant utilizing the Texace Coal Gasification Proce ss in 1977 atOherhausen-Holten, Germany. The dem ons tra tio n plant has bee n in ope~atlo nm o r e t h a n 4 y e a r s . O v e r I 0 , 0 0 0 h o u r s o f o p e r a t i o n , w i t h a t o t a l t h r o u g h p u t o fmore than 50,000 to ns of coal, have been achieved. Eleven d iff ere nt types ofc o a l h a v e b e e n t e s t e d . T h r e e o f t h e co a l g r a de s u s e d w e r e s u p p l l e d f r o m t h eUnited States.

A n u m b er o f v a r i a b l e s t h a t m ay a f f e c t t h e c o a l g a s i f i c a t i o np r o c e s s i n t h e C a s o l i n e P l a n t a ~ e :

( I ) G a s i f i e r t h e rm a l p e r fo r m a n c e

( 2 ) E g f e c t i v e u e s s o f a s h r e m ov a l a nd c a r b o n r e c y c l e s y s t e m s .

( 3 ) P u m p a b i l lt y r a n g e o f h i g h s o l i d s c o n t e n t s l u r r i e s .

(4) A s s e s s m e n t o f u n e x p e c t e d c o r r o s i o n , e r o s i o n , a n dr e f r a c t o r y l l f e .

II

L

I I - I 2 . 5 - 6


7/115

C I T h e t e m p e r a t u r e s mad pressures involved in the Gasoline Plant arewlthi~ the range for which equlpmont has been eupplled for p et ro ch em ic al andproce ss pla nts . Som e key items in this process area are slurry charge pumps,s luzTy prehe a t ing , ga s i f i e r burne r , and gas l f l e r /w as te hea t bo i le r sys tem.

T h e r e m o v a l a n d h a n d l i n g o f s l a g f r o m t h e g a s i f i e r a r epa r t i cu la r l~ a rduous appl ica t ion s for va lv i ng . Spec ie1 a t t en t ion was appl iedt o t h e d e t a i l s o f v a l v e d e s i g n . S a f e t y i n t e r l o c k s o n v a l v e s a ndins t rumen ta t i on for sequencing prevent malopera t to n of the lock bopper s ys temfor s l ag co l lec t ing and dumping . The gas i f i c a t i on uni t s a re provided wi th~'larmo to warn of abnormal cond it ion s. The purpose of the al arm sy st em is toa l low ope r a tor s to t ake cor rec t ive ac t io n be fore an au toma t ic shutdown i si n i t i a t e d .

C

The e f f i c iency of the proc es s can be a f fec t ed by threes i g n i f i e n n t v a r i a b l e s i n c l u d i n g s l u r r y c o n c e n t r a t i o n , a s h c o n t e n t o f t h ecoa l , and melt ing point o the ash. The gas if i ca t ion fac i l i t ie s were des ignedfor a range of coa l ana lyses centered on the de s ig n c oa l used in th e nor malo p e r a t i n g c o n d l t o n o An i n c r e a s e i n a s h c o n t e n t , a d e c r e a s e i n s l u r r yconcent ra t ion , o r an inc rea se in combus t ion zone t empera tu re r equ i re s morecoal and oxygen fee d per Btu of hea t ing va lue of gas produced. This res ul t sin higher ope ra t ing cos ts than provided in the Opera t ing Cost Su~nary.

T e c h n i c a l r i s k i s r e l a t e d m a i n l y t o e q u i p m e n t l i f e a n dmaintenance requi rement s , which inc l udes the ra te of wear of the re f rac tor y.Lif e of a t lea s t a year is expected. Two spare gas if i e r t ra ins were inc ludedi n t h e d e s l g n s o t h a t r e p l a c e m e n t o f r e f r a c t o r y c a n b e s c h e d u l e deequen t ia l l yo The spa re g a s t f l e r t r a in s a l so a l low an aggre s s iv e program ofrecognlz lnE and sol vln ~ problems to be earr led out by per iod ic rot a t i on ofuni t s fo r i nspec t ion , p revent ive ma in tenance , and ma in tenance .

The s lu rry charge pump~ provided are commmere la l ly ava i la bleproven equi pment , and requ i re no sca le - up or ex t r apola t ion of de s ign . Thepumps a re d i scu ssed In the sec t i on cove r ing Coa l Gr in ding and S lur~ 'yP r e p a r a t i o n .

I I - 1 . 2 . 5 - 7


8/115

The gas l f i e r des ign p re ssu re o f 900 p s i and des lgn bas i s( s lu r ry concen t ra t i on co~, t ypes , gas l f i e r t em pera tu re s , e t c . ) a re cons ide redw e l l w i th in commerc l a l u se and conse rv a t i ve ly se t . Burne r rep l acement i s as lmple mat ter and adequate spares are s to cked . Cas i f l er lock hopper va lve sare cr i t ic a l i tems, but operaeing uni t s have confi rmed techni cal adequacy ,

Re~c t l onsw i th h lgh -pu r i t y oxygen p roduce l a rge quan t l t l e s o fhea t and requ i r e ca re f u l mon i to r ing and con t ro l . As descr ibed he re in , t hegas l f l e r sy st em i s h igh ly i n s t rumen ted to p rov ide ope ra to rs w i th i n fo rm a t ionon the ope ra t i ng con d i t i ons . Th i s i n fo rm a t ion i s i n t eg ra t ed i n to a t r i psystem that shuts down a t ra in au tom at ic a l ly i f unsafe condi t ions ar i se .

The was te heat boiler system is a very critical Item sir itrepresents simultaneous gas cooling and r eco ver y of a majo r port ion of thehe at (steam ) utilized in plant dr ivers . The design is based on the successfulo p e ra t i ng e xp er ie n ce i n t h e R u h r c h e m ~ e d e m o n s t r a t i o n p l a n t a t O b e r h a u s e v .S p e c i a l s o o t b l o wi n E e q u i p m e n t i s u t i l i z e d i n m a i n t a i n i n g h e a t t r a n s f e rs u r f a c e c o e f f i c i e n t s a nd t h a t s o u r c e o f t e c h n o l o g y i s u se d f o r m a t e r l a lselection.

T h e m ~ a n s b y w h i c h s l a g i s d i s c h a r g e d f r o m t he g a s l f i e rrequires specl al attention during operation to minim ize the risk as soc iat edwith the scale-up from existing units.

A slg uifi can t risk results fro m the uncertainty relatlng toc o r r o s i o n r a te s i n t h e c i r c u l a t i n g w a t er s ys t e m , a l t h o u g h i n f o r m a t i o navailable at present suggests tha t this corrosion may not be unusually high.

U n c e r t a i n t i e s a s s o c i a t e d w i t h t h e d e s i g n an d o p e r a t i o n o fcoa l s lu rry heat ers do not pose ser ious r i s ks as the p lan t can be opera tedsa t l s f ac to r i l y w i thout t hem.

I r - I . 2 .5 -8


9/115

C I J I I n g e n e r a l , t h e K a a i f i c a t i o n s e c t i o n c o n t a i n s c e r t a i nequipmont mentioned above tha t has re l a t i ve l y sev ere op era t n8 cond tJ .on e;howeve r , commerc ia l ope r a t ion has proven the adequacy of the proces s . Inc o n j u n c t i o n w it h c o n s e r v a t i v e d e s i g n s a nd a d e q u a t e s p a r i n g , t h e t e c h n i c a lr is k is cons idered minimal .

I I - 1 . 2 . 5 - 9


10/115

E . p~ocssa ~low andC oncro !.Di aKrnm (l,,~cludlns Mate ria lBslanco)

Tho Pro caa8 Plow and Con trol D~agram fo : Ga si fi ca ti on UniC 21i s a s f o l l o w s :

Drawing No . Titl.___~e

D-21-~P-INP PFCD Ga si fi ca ti on - UniC 21

' l m m , w , m . ~ ,

t

Z Z - 2 . 2 . 5 - 1 0


11/115

. l o s , ~ , , m . e .. . . . : , ,t " , ~ , I ~ I , 4 ~

A

m

e

c

m

D

m

E

F~

I

F i' 0 X O O U L (. . . . . v . . T O I IO ~ U L ( tM A K ( U P I A T I ~ ~ I

~1 0 K O O U L r41 0 U O 6 U L I :T O ~ [ Z I

1 ' 0 _ , 2 : , , 5 i m ) O ~ ( ; ( [ ~ ( ~ ,, , :T O M O O U L (T O ~ [ I t II

I O - t ;~ , - u e - t " " ; ) r E ( o C O A L

C I ~ T F [ , ) C 6 A L ~ Y G ~

CARBON 3211TTI 67 ,00 - -HYOPlOGS'N 2 ~ 05;. 4, O0OXYGEN 31 ~ 7 &. SO 43 ~ TSON ~ I i 5 ? T S ) l , 2 0AItGOla ~ ~ 2 ?StlSULFL~,, I0 . 250 3. l lOCHLORINE 480 (1. IOA S ~ S I .A C ~ s . ~ z z o l e o: ~ T T OT AL 4 9 G, 2 5 5 ~ 4 4 2 , S lO! I fAT[R 46, ~ j l$ ~lET T OT AL S~ T 1 1 4 I 0 0 , 0 0s tP p , O n T s , ~ ] s , 3 t oS l ,r O ~ 6 . ] z i - -OT ~ L O XXY D R Y 1 2 , 3 5 2

In,

S L U R R YP I ~ A R A T I O i ( III 1

r

lIi[IIII

rIi

( [

I~ T / I I A T E R R E C 1 f C L (

r ~ ' - '- " ' ' ' ' 1 I

~F I I , I2 I

K f ~ a l W T I Q N3

~ 1 n I ~ - 0 ~ . 1 1 ~ 1 . ~ < ~ ' ~ . ~ P ' I' ~ I" ;' I" F . . . . .i C ~ . , ~ p m l . ~ ,1 , . ~ ' ~ I ! . r : - ' 'J r ~ i I ~ 1 i F . . . .I , I , , , , , ' 3 ~ d . _ .i i ~ & , , ~ n I I . r t I , tA d ~ I I t - . - - .


12/115

~.,,~ ;~I .~;~ , ', .~.T~'I~.~ '~. . , :~ , , , . , , , , e . . . .

, ,

S C R U B B E R S Y S T I~ U

~ n ~ ~ ~ ~ ~ ~ ~ ~

II '

6 I

PROCESScOarl1tSATr-' ~O -S$-U P"I XP J

7

14OT 2~h Tile RASIF|CAT[OI~ UUIT COHSt~TSOF 111ENTY-TWO Tg~]N S (~'4 ) . |0 OPSNkliNO AND i rd;AR~S~| H F O U R ( 4 ) UCOULESaMOOULE I CONSISTSOF TRAIHS ! TXRU E -IS OPERATING, / ~#ARi~IMI~IULE 2 CON$1575O f TRA INS T TX RU I I -15 O PERATING)M O DULE 3 C0~ | $1$ O F TRA ~H$ 12 7X RU I? "(S O P f ~ A T Z H 6 , I SPARE)XOt)ULE 4 COHSISTSO F TRA ~N I ! THRLI 2= -(50PER/~,T]I(GI2 , K A ]E RLA L O A LA f lC( S ~E A I IS A I~ S TE AM RA TEARE SIl~i lH AT HOR3AL OPERATXNOCOHO]T]ONSFOA ONE MOI)UL[ OF 5 GUZ F]ER TTLAZNSOF kHO i l ]NA L 50 .000 8P D CA S O L[H( P LA NT.

s ~ I , ,-B Z . .W - l l n ~

s o ~ F e ~M T (n C 0 - 2 3 - ~ - e ~ 1

e ~ m ~ i o -s z .- w -n n ~ e )

@ [ ~ ( ~ , ~ s , o c o ~ ,z rr I o " ' " ~ " ' ' e >

CO~OKERT

_C_C_C_C_C_C_C_C_C~~COc o |E |Ju"HI SC OSTO TA L o la f: HIOTOTALL B ~ I ~~ E C U L I ~ I I 1 ' .I~SCFDa,,FS~kF

~ o L . m . u m . Z2 . 0 2 ~ , ~ 1 91 6 . 0 4 0 . 2 02 0 . 0 I 4 ~ e 144 . O l IT , B I2 0 . O 2 O . 4 839. 94 O. IG~ 1 , 0 6 I . Z ' /~o , O T o . o8I00 . O 0

RAW GASGA$ZFICAT]OltLB M O IJHR15. 645 . 2T

B 5 . O Gtot 9,40o21T ~ G g T ~ to2O 5. TS6 9 . 0 7550, 2~143 . 2ZT . 4 6152- 65T4~ OZO. 17I ~ , 4 0 6 , 24 0: '0. OB

6 7 4 , I87 44 )5

' ~ P P F , O VA L I I . , I . , , I I I

4@

70 EASTe~ T ( e T e ~ G t o - z ' /- L e -t m . >

SLABT O o zse o s~ . I o - i ~ . - o . ~ >

CO ld ' RE NT

H Y D R O G E N

EFFLUENTU T RI.ZVH~

S lA G TODISPOSALU Y H R3 ~ ) 5

OXYGEN ~

SULFUR ~CHLO ( ~( ( iASH/9.,AG 114~1 76574[[ ]RY TOTALk A T i~ 572971 317 ' / I

TO TA L 574020 110740

D2 l l~ l NP . DO ,4U . S . D E P A R T H I : H T O F E N E R G Y

V J ~ G R ~ C : E & C O . ~ D m J c ~5 9 , E ~ B B . P . O .COAl . . - T O - H E - I' H A N O L - T O - G A S O L ] I ~ E P L A N T~ m r ~ m

PROCESS FLOW Ik COW~,ROLD ~ G R ~ I ~ AGA$~F'JL~ATZOR ~ 21t

o

m

A

D

'6


13/115

F . P , l o t ,, , P l a n /G e n e r a l , A r r a n g e m e n t D r a w i n g sP l ot P l a n / G e n e r a l A r r a n g e m e n t D r a w i n g s f o r G a s i f i c a t i o n

Unit ~1 are as f o l l o w s :

D , r a ~ n ~ N o . Titl...__~e

D-21 -PD- INP

D-21 -PD-2NP

P l o t P l a n - U n i t 2 1 G a s i f i c a t i o n

P l o t P l a n - U n i t 21 G a s i f i c a t i o n

D - 2 1 - M H - 1 R P G e n e r al A r r a n g e m e n t - G a s i f i c a t i o n - U n l t 21C a s l f l e r A r e a - P l a n a n d E l e v a t i o n

am

(I I - 1 .2 .5 -11


14/115

. . . . . . . . . ~ ` ~ ~ i = ~a ~ i~ ` ~i m ~ m n~ r i~ < ~ -z t ~ ~ ` ~ ~ [ J ~ y .~ " ~ - . . . . . ~ . . . . . . . . . . . . . . . , . . ~ . t . . . . . ~ , ? t ~ , . , l . . . . . i , . . . . . . , , . . . . . . . . . .~ ,1 I 2 I ~ I

A

B

,t ,

N04 t .

I,q ,I ' , -, , Ih i. J

n ~. J

M A TC L I N ~ N , IO 0 2 5 ' - 0 'S L A G C O N V E Y O R S L A G C O N V EY O RA N D P ~ A R EA A N D P ~ A R E A!

]II

G A S I F I E R SA N D H E A TR E C O V E R YS Y S T E M

] D R U M S! A N D. _ _ - - I E X C ~ I ~ E R

\l ' I l l i i l l l i i l l l i l i i l ~

G A S I F I E R SA N D H E A TR E C O V E R YS Y S T E M

I i!iD R L V ; D R U M S i D R U M SA N D ' iH E A T - - , . - , A ND A NDH E A T ! H E A Ti E X C H A N G E R SX C H A N G E R S [X C H A N G E R S iii

; I: i, . " 1 r ' - . . . I I ~ . - ' 7 - ' 4 . ./ I - . . i i " ' / ! / j . . . t " l ! " . . . . ./ I - - > ' q . - / ! / > < : ~ " " ' ; : > ' " "" ' d u . - " I / - ' - . _ L . ~ . . . . - - I L . . " " "

n i

| . . . , . ." 1 " " I ' T I ~ I ~ I ~ E C T I R" - " l" / I - -

C A R B O NA N D A S HR E C O V E R YF A C I L I T I E Si ui B U R N E R C O O L I N GW A T E R C O O L I N GF A C I L I T I E S

m u , , i iC / L R O A D ! l M A T C H L I N E N . 9 6 : ]0 ' -0 '

e , O , 3 C A I I . l r O M I o ~ l i M r pi t @, l-~i-,a IILI .JeLl HlilGS~H.! "

.>F ~ O ~ I C NF ~ C L I E N t . . '"F ~ L ! C E ~ i : .I ~ C L I . , '.


15/115

, , , ~ ~ ~ e ~ , ~ ~ ~ ~ , ~ ~ ' ~ ~ N ~ ~ ~ ' ~ t , + , , , , , ,t o I '~ ' , " + ' J i a i p ~ i I I I k d ~ q l _ _ I ~ J I I I I I I I

S L A G C O N V E Y O RA H D P U I ~ A R E AI

G A S F I E R SA N o , ~ T ~ ,R E C O V E R YS Y S T E MI , . ' I

D R I . ~ S D R U M SA N D AN DH E A T H E A T i ~EXCHANGER "XCHAHGER'C

- - . . . . < : : " " i : . : . ~ : : +I - 4 1 . 1 _ , _ _ - . J ' " . . . . . . . . . . t " - . . i! M A T C H L I N E N . 9 7 6 0 ' - 0 "" "., - - 7 - i',., .," ,

i + -/- - Z

; \/

D . ~ , , , D ." ~ ' . . . . . ' ~ - - I I ~. .: .:; :" ....~d.p~OV. L I~ ,. I Je |- '. L '- - ~ .n ~ t ; ~ ~ l - - " " ' " ' l O S i~ - z s - e a l Z 4 E~ H , ~ CO4PJ~IY~ m c N ~ , w ~ I ~ a l I ~d , e~ O ~ .l P A S A I ~ C ,'N ,. ZF O e~ In i

N O T E tI .THI$ PLOTPLAN S Of: MOO~E el OF 4 MOOULES2.WOU LE 3 15 IDENTICAL, ~ = ~ FOR MATCIILINECOOfd)KATES,

0 1 9 2 0 4 0 & O , S O 0I - - JS ~ l t , ~ I " Z O ' , , O 'U , S , D E P A r T I H E N T O F E I ' E R G Y

e ,~


16/115

. ,... , ~`~ '~ '~m ~'~;~`~z~;v' t~m ~:~t~/~`~J t~ ~R'~L~ ~;y~!~I~I ~L~& ~%S ~:~ ' ' , '~ ' II ' ' !~ ' , ' , '~ ,,~ ' ,,~ ' ,,~ 'v,' ,t4~l ~.~.'~Im,,e ;~{#~.u.' f,I, ' -,r,~:s r.'~ '~ ' ;*.v~ :,; ' ,., , '~"~ ' .~"~ '~."rt ,~t~.' t ; ' ,,"~..~,' rt i , e

I I t ';~;S 4 ~ ,' rN M ATCIt L I N E N I e 0 2 5 ' -0 '~ ,"

" A

0I

,. s

.. J

M A T C H L I N E N . g T 6 0 ' - O '

,,ip0r r ', , , J

D

SLAG CONVEYOR SLAG CONVEYORAND PUMP AREA AHD PUI~P AREA :

. I I l l * ~ } ~ . I I i l l . I ~ l l i i * l I i l i * ~ l l I i i I i ' ~ * l I ~ I I . ~ i l I I I I l I l . ~ l I I I I i I l I I i I I I I * g o ~ I l l I l l I ~ I m ' l l I I ~ I i * * .

f

i

i ~ ~ '

COMPRESSOR AR EASEE iTE 3

GASIFIERSA~5 HEATRECOVERYSYSTEM

\ \

DRUMSAND HEATEXCHANGERS

DRUO~ISAND HEATEXCHANGERS

. i . ~ * " i~ ~ * * . , ~ . . ~t

~ = . , L , ~ .~ * ~ "

!' T - i- - /

//

: \" - - 7 - - ~// \i, \

i

f

DRtJ~AND HEATEXCHANGERS

GASIFIERSAND HEATRECOVERYSYSTEM

DR ~AND HEXCHAN

" " " " ' " " " ; < " i " " ' " "" " "NTERC OI~ECTING~ IPEJlA " '~1 . ~* ~* ~* "~I I " -SOOT BLOWERS

SEE NOTE 4

BURNER COOLINGWATER COOLIHGFACILITIES

i

m

ill,m i , i i ~

'IIlL

II

I i i ' ! 'i ! ! ! , IC/ L ROAD& M A TC H L I N E N . 9 6 3 0 ' - 0 '

I I I I I " :I ~ L I ~ I ~ c s ~ " I ~ . ~ | ~ , ;

| i ~ t t J , x ~. l ~ l ~ " ' - e I t s s o z c t , ! .~-1 ~ ~ l " ' l " ~ I " ~ l ~, IL i m ' m i . . . -I


17/115

I !~ - L

i , I , . J r l i , L I I i i i I l l u I I i ~ . . . . ~ i l l I

i l ~ " I , , r ' i -J - -' ~ ' , i n l i i i O " I I n i l~ , ~ , , ,B"t:~:;,)" SL Ag CONV EYOR,,:A;"~,,r~ AND PU MPAREA - ; , . . ' , ' ! A, t , I. . . . . . . . . . . . . . . . . i . t .e~ '4 L . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . . .

" \ i / Ii _ ] H I , , , , , i,i x \ / ,

, i GA$1FIERS PRO CES S

HEATEXCHAHGERS

. ,o

i AND HEAT C,ON~'ROI .. RECOVERY I~J ILD INGI SYSTI.:~II ~-4~o~i / \I , * % .i - ~ / %

i DRUMS SATE LLITEAND HE AT [- ' - - ' - - '1 MAINT. BLDG.il ! EXCHANGER ( ~ S G - ~ Z ~

i

l l l l l

. . . ,_ ..._;;- .JR ~elleOVkL. . . . ~ . . . T IEVtlEI

CARBONAND ASHRECOVERYFACIL IT IES

I ' i i / z p ,I I ~ , , c , . - J I ~ 1 2 -Z S o II I T I l l | I I A U P I I L PJIlllOlll COIPAJlY

! ~ 1 I

I

GO

ILl

,. J.5-,

. J

J

H O E ,1 . I X | $ I % 0 1 ' P L A N I S ~ " ~ e 2 O F 4 U g B U L (S .~-ilOOULF' 4 IS I~]fr lCA l., ~ FOR I~TatL IliECO 0 1 tD I I~ ES AND O TIEA I IS( I IO TEO , i I~OCSS .~ l~oL151 .O ~ e~ . & ~ . M E ] S 4T E LL I T E I A i l l T . B I . D ~ - l l ; e ~ !] . O I l ~ E S S I I ARF.4 LO ~ TEI ) I i i ~ q( S I ~ J l O O U L I ~ 0 3 ~ 8 4 ) . ~ Y .

4 . S O O t ~ LOCATED IN M O O U L( o 2 ONLY , ,~ W 1 5 , M .L X G I 3A . E~

0 IO

US . DEPARTXBTrOF EHERGYI e ~ n V J I , G A ~ I E & C O ,'1 ~ B -~i ~ - T O - ~ - T O - ~

' " " ! ~ O T ~ I ' ; : . , , ~ I - ; ~"1 U N IT 2 1 I . . - i . - - . . , , ~ GA SIFICA TION | D-E I -PI )-2N P 5 --~-~'n l l i i i i i / i i I6 I

E

;L

i


18/115

h ,+

4c

0

P Z , + M I ~ + ~ t 'T N

O

{

M A dN

4,1

, , _ . ~ . + L . < . e , + ~ . J . + e ~ e . . , ;

~ / L T EJ?

PULLEY . , ,

M 7 " 1 l / "1~ '~ ..I*UpPZ '

M M ~ x ~ ~ ~ 4 D M 9 5

A

r v r e , ~f , 9 0+ . ~

, , eU ~ L + - - . , L - J .----"I +" ~ - - - - - , ~ ' L T ~ "~ / // :.

:8 ~ T C O ~ I K

".%m f

+ ic : o '. . ~ ' . ~ , " , t, T o ~ ~ " . :

- . ~ wn~.,~,.~o41~ ' . ,

" - ( c o ~ v . + v , e . )

+ ~ , + , t , S E C T I O N1 " , 4 0 1 . 0 " ~ .

.,,~.~-+e"+91~I~ I . D - : ~ 9 - P D - 3 , t I P , + , . + : , :

~o .z ? P , ~ l ~ / t - . , i " / 7 / / ' *

4 : ~ ' h , , / ~ - o . j. _ ~ , + ' .- + ~ 1

L " : - " I co ,,+ .-~ , ,o i l

+ ; + e "

[ ~ - ~ " " | . . . . . . ~ o , o ' - o ~ . c " ~ ' ~ 4 . . . .. , ,, . . . . . . . . . : - ;_ , ; ~ . + ; .+ ;

. - , - - - . + . - + I+ . '. F : + , , . , , . +~ 1 i i~ l l ~ P i - -. . _

1 ' - - - ~ ~ "_ _ .~ _ '. # _ _ E ~ z _ . ~ + ' .. Y . .. ~ , " ~ "_ _ . _ < z _ , ~ . , "v v . .e . e -, . , , ~ " ~ " ~ I +/+, . , L l

] . . " " D :~ ' ~ ' / ~ . ~ , ~ ~ _ _ ; . ~ , ,

mm

" ~ . ~ . , , e ~ , . m , ~ l I I I I I I I, m ~ r ~ u , . . ,R ~ , ' ~ , ~ , ~ . . * : t l l , , " "I I ~ 1 I I I[ i l ~ : ~ T : ~ - - - ~ m t J ~ t ' t ~ z : " ~ t - ! ~ / I ~ + 1 I I I1 II t I II I I II I I II 1 ! I

4 - b - b . - . i D I ~ 4 ~ R I P T IO H JI ~ ,1 ~ I -" /. -/ ~ I, + .. A I M J + # + I " l ~ . ~ ' q :I = I A , ~ - ' : ~ " , ~ I P s I ~ 1 ~ , / ~ 1 ~ , ~ t: - : + +~ !;.I I . O . l . o A t t I " ~ ' I ~ l " ' l m ' J l ~ m m l . ~ _ . - ,4 1 ,


19/115

,,,~,~

d'!, ', [ ~

,~,~

i ~ e L r P R E ~ S

. , , . = o o ~ . . . . . . . . . . . . . . l i to . , ' , ~ , - ~ - " , ' , ' ~ ~ I!1 " .

, S U ~ C o N V .

~ ' ~ w , ~ , ~.~ . . ._ -. ~ o i , o , : o ' ~ ' . ~ " . , ~ , o "

i , l ,~ i z { ~ , ~ , ~ , , , , . , ~ : ~ . [ 1 _ [1 1 _ [ ! ] [ . 1 . ' ~ 1 _ [ . ' . 1 _ L l - [ . ] - F " e ' ~ ' a e ~ ' "

SECTION: ~, W , , 9 . 7 B 4 , 0 0 . q~ EY.~POR R't 'OR5

14 O ~ . "Eo o l 4 +. " - " J ~ L T L I M E

~ - ' _ L B ~ , m om!l -

. ~ C T / O / J @1 % I 0 "

i i m a im , l ~ l !7- -t " . l l m ~ l r " ' , , , , ,

_ f l a . . S A B I r I a m

' r " . I m , ' r " - - s . - t l m "i i m l ,

. , ~ , o ~ , . . . ~ - , - ~ I . . . . 1 6 , o . t . l , o , o , q _ 4 ~ . . r D, .L,_,,.~ ,= e L .~ '~ m I r c v u I . . ' . - " - . I I m T H E R A L P H M . P A R S O N S I ' O M F A ~ i yPASAD EN A. C AL I F OR N I A i

I , :o, I

U . S . D E P A R T M E N T O F E N E R G Y. A S K ~ ' r . .. . ~ R . G R A C E & C O . K EN TU CK Y

5 0 . 0 0 0 B . P . O .C O A " T O - M E T H A N O L _ T O C ,A S O U N S P ~ N T. . . . . C ; ,: N ~ . A LA R R A N G '.S .T J ,.,s O T E O 2 ~ 0 0 - j ~ i , ~ l ZG A S I F I C A T I O N - U N I T 2 1 [ I I~ S m l e R A R E A - P ~ . ,~ E LL WA T,0 NS ' ~ ' 2 1 " ' - M H - I H P I

A

D


20/115

0 ~ , i n l ~ p ~ l g l ~ I n I B ~ I Q J l ~ 1 4 w~ q , I ~ r f , i I t r ~ ,O r e . ~ J l ~ t ~ J ~l , 4 1 0 1 , p ~ I ~ W, I D . . . .

g. Si~ Lin e Dlasram

Single-Line Diagram for Gasification Unit 21 is as follows:

,Drawing No. Titl._~e

D-51-EE-3NP One-Line Diagram- Uuitu 21 and 24

II-1.2.5-12


21/115

A

I234

2 I

~ R t o , ri "

U/U.L2t rvo FoR 4 J/ODU/E.~#l l , S/WA ,1 ~3 4 ,44,1~ AY

I~'~ 1~4"t

/

21/2"5 MVA~ J I 4 . 4 K V -

"- -T -- ~-o~o~'---~ ~ t 'U ~ J . ~_ '~ L 'U ~ " - - 7 - -

4 teOV .30 - .OP'A~ -- - / ,f ' rSLS -- '3 -~A. I 4 t~OV

ra~ f ez rR~ I1~ re s rtt nt~ ~ z r ~ ra4 ra $m r r t ~ r t ~ r m o r m ~ r ~ r r a ~ r t ~ T R i o ra erata rat: ma~ r m s m ~ e r e ~ rata rat: rat~ ret~ ~a t- -, ra t s r e t ~ r ~ o m z t r e r ~ I lRt~ r e t ~ r e z o razt ran

lr yCOW,, TO 41~0 VOLT COR e, TO 4lt;O VOLT

M.$W51-0106TI/ .COAL GRIND ING

,t4.SgVEI~ 5 I-OZ'OST

1 2 ~

12"15o6 lira$ 4 . 44.16 KYZ' m

4160V ~CC 4160V ~CC

TRSm l r

)

[

( )

1 ~'~ " t ._ ) (

k~m,mVflON1

_._.A . . .I

~ qtT IOf4 !I i, , I I _..I ' i "'''-'',---,.o.i , ,, ,i , , ~ , ~ l , , ~ l, , o , r . - - i - ~ - ~ ' - I I " I ' 0 " I " I ' ~ . ' = ~ ' . P ' - ' I: i s I " ~ '


22/115

. , . . . . . . , ~ , , , ,, . : ,, ~ ' ~ , ~ P , , ! t ' ~ : ~ : ' , ' , . . ' , ' , ~ ' , f ~ ) ' ~ , ! ' , ' / ~ , " , , h , , , , ' , ; : : ' . , , , ', , , ' , ~ , ' , , : . , , , , . , , , , ,4 ~ , e ; l, H

i l l I I , , . , , , , ,

I

(

I

1 04 , 1 6 1 NAl' lEFT

A

T Y P I C A L f f N I T 2 1 T R A I N m. 4 . I I I I V/ ~ A r L i lr l rTO ~Cll -i .. . ~ .. .. i. TO AC~

I

_ 4 1 6 0 V M C C . , l ~ - " i 4 1 6 0 V M C C

) 0 0 F " " '!A

! I ! t! !

. J (

NOTE I

()

TO4,16XVAT RICtiT

)

T Y P I C A L U N I T 2 1 T R A I N

TO~ C 3 - i . . . . ~ . . . . w . TO ~ .a4 1 6 o v . . c c _ _ j . e ~ . . . .

/ / 16-~":>"~!OOF ,,o! !

m r n l l m ~ l ll . rl ~ t l l t J i n ~ n t l A , , o , i i - - -m l i , , m , ~ l ~ i r , R i m m l i i l l " , " I m ' I I I I , i l ~ l ~I , , l= , l ,i l , , i i ~ , . I , - , . , , ~ e . l l " " " " - - I 'F ,L ,= ,~ ,:, , . , ,, , r ,~ ~ l lm m I I '* " " " " l l l ti t l i I l l l l l l A l l

i4 0 s

i l

YI ~ O HL V

TO4. IIIXYAT RIGlcr

D

NOTESal, PROVI~Al l, Alh't, IRTF..~ AT ALL LOCATIOn3 ARKEO

, , , , , , t ' ~ l ~ l

m

I . L

, , , m m l | , i iU . S . D E P A R T M E N T O F E N E R G Y

s o , o o o O . P . D . ]. _ C O A L - T O - M E T H A N O L . - T O - G A S O U . N E , P L A ~ , . m [ ,

1 1 i I F I 4 I # O N l l ' l l i l m ~ . . . . ~ / -% , !: ' " : , " < " - - ~ " I O - 5 i -E E -3 N P i , . ~ , i , _I |


23/115

1 . 2 . 6 O X Y G E N - U N I T 22

T h e p a r t i a l o x i d a t i o n p r o c e s s a s s o c l a t o d w i t h t h e T e x a c oG a s l f l c a t l o n P r o c e s s (T C CP ) r e q u i r e s a n o x i d i z e r t o n u s t a l n t h e p a r t i a lc o m b u s t i o n o f t h e c o a l f e e d s t o c k . T b l s o x i d i z e r i n t h e f or m o f h l g h - p u r l t ygaseous o x yg en I s s u p p l i e d f r om a n a i r s e p a r a t i o n p l a n t w h i c h c r y o g e n i c a l l ys e p a r a t e s a i r i n t o i t s ~ a J o r c o m p os e r, i s o x y g e n a n d n i t r o g e n . A l l o f t h eo x y ge n i s r e q u i r e d f o r t h e g a s i f i c a t i o n p r o c e s s w h i l e t h e n i t r o g e n p r o d u c e di s u s e d f o r p r o c e s s , p u r g e , c a t a l y s t r e g e n e r a t l o n , a nd b l a n k e t i n gr e q u i r e m e n t s i n t h e p r o c e s s a n d o f f s ~ t e u n i t s .

A . , B a s i s of D e s i g n

T h e d e s i g n o f th e a i r s e p a r a t l o n ( o x y g e n ) p l e a t i s b a s e d u p ont h e u t l l l t y s u p p l y o f 2 5 , 00 0 s t p d o f o x y g e n a t 9 9 . 5 X p u r i t y . T he o x y g e n i sc o m p r e s s e d t o i , I 0 0 p s l g t o f e e d t h e T CG P. D ue t o t h e l a r g e r e q u l r e m e n t o fo x y g e n , t e n p a r a l l e l 2 , 5 0 0 - s t p d a i r s e p a r a t i o n p l a n t s ( t r a i n s ) , w h l c h a r eb a s e d o n t h e l a r g e s t c o m m e r c i a l l y a v a i l a b l e , a r e I n c l u d e d i n t h e d e s i g n .T o t a l ~ I t r o g e n p r o du c e d f r o m t h e s e pl a n t s i s a b o u t 8 , 5 0 0 s t p d a n d a v a i l a b l ea t 7 p B i g w i t h s m ax im um I0 p pm v o x y g e n c o n t e n t . T h e f e e d a n d p r o d u c t s t r e a m sfor this unit are shown on the next page.

B . P r o c e s s S e l e c t i o n R a t i o n a l ei I J

A su mm ary o f t h e p r o c e s s s e l e c t i o n r a t l o n a l e d l s c ~ s s e d b e l o wi s b a s e d u po n t h e e n g i n e e r i n g t r a d e - o f f s t u d y p e r fo r m e d f o r t b l s u n i t .

I . O xy g e n P l a n t V e n d o r C o m p a r i s o n . I n v e s t i g a t i o n s w e r em a de o f t h e p r l n c l p a l s l r s e p s r a t l o n p l a n t s u p p l i e r s i n o r d e~ t o e s t a b l i s h as o u r c e o f i n f o r m a t i o n f o r t h e p r e l l m l n a r y d e s i g n . T h e s e i n v e s t i g a t i o n si n c l u d e d A i r L i q u l a e , L o t e p r o , U n i o n C a r b i d e , A l t o n , an d A i r P r o d u c t s . T hea p p r o a c h d i c t a t e d f o r t h i s u n i t w as t h a t th e a i r s e p a r a t i o n p l a n t i s ap r o c e s s uti l l ty wbich i s r e q u i r e d t o s u p p l y t h e s p e c i f i c a ~ ou n t o f p u r i t yo x yg e n n o t e d a b o ve f o r p r o c e s s r e q u l r e m e n t s . T h e r e f o r e , t h e s e l e c t i o n o f ana i r s e p a r a t l o u p l a n t v e n d o r w a s n o t n e c e s s a r y an d w a s n o t m a d e.

I I - 1 . 2 . 6 - 1


24/115

B a a e d p r l m a r l l y o n t h e e x t e n s i v e ex p e r i e n ce b y ~ l rLiqutde in i t s supply o t la r ge-s ca l e oxygen p lan t s for the SASOL fac i l i ty andlower capi tal cost, It usa d eter min ed that data for the prellmlnary designwould be obtained from Air Liqulde.

2, G a s e o u s O x y g e n C o mp r e s s i o n vs L i q u i d O x y g e n P u mp l .n ,T w o a l t e r n a t i v e o x y g e n p r e s s u r i z a t i o n p r o c e s s s c he m e s w e r e c o n s i d e r e d :8 a s e o u s o x y g e n c o m p r e s s i o n a n d l i q u i d o x y g e n p u m p i n g . O f t h e 1 v e o x Y8 e nplar, ~endors c o n t a c t e d , none had c o n s i d e r a b l e e x p e r i e n c e i n l i q u i d o x yg e np u mp ing . Ai r co , A i r P r o d u ces , Lo tep r o , an d Union C ar b id e f av o r ed gaseo u so x yg en co mp eas lo n . Ai r L lq u ld e was o p en , h o wev e r ; i t s v e r y ex ten s iv ee x p e r ie n c e r e c e n t l y i n th e SASOL p l a n t s i s w i t h c e n t r i f u g a l c o m p r e ss io n So500 p s t g ,

Fr om the oxygen plane vendors' comme nts, it was concludedtha t the c u r r e n t i n d u s t r y c o n s e n s u s i s t h a t g a s e o u s o xy g e n c o m p r e s s i o n I np r e f e r r ed to l i q u id o x y g en p u mp in g, and g aseo u s o xy g en co mp r es s io n wasr e sea r ch ed f u r th e r .

3 . Gaseous Oxygen Comp res sio n , Based on cur r en t commerciale x p e r i e n c e , t h e s e l e c t e d s c h e m e w a s c e n t r l f u g a l c o m p r e s s i o n t o 6 1 0 p s l gf o l l o w e d b y r e c i p r o c a t i n g c o m p r e s s i o n S o 1 , 10 0 p s lg . S u l z e r an d D e m a gconfirmed th at is 1982 the re were centrifugal oxygen compressors o pe ra ti ng at1 , 5 0 0 p s l g a n d t h a t c o m m e r c i a l e x p e r i e n c e i s b e i n g d e v e l o p e d f o r a l l -centrifugal oxygen compressors.

C. Pr o cess Desc r ip t io n

The eu u lp men t a r r an g em en t and ma te r i a l b a l an ce f o r th i s u n i tare shown on Process F low and Co n t ro l D lag rams D-22-HP-1NP, -2NP, -3N P, -4NP,-SNP, and -6NP.

I I - 1 . 2 , 6 - 2


25/115

w

(

C .

CemponentJ . .

N2br02Total dry, lb mol/hrH20To~al wet, lb mol/hrTotalD lb/hrPressure, psiaTemperature, oF

Feed 8treamo: i , J _ , , ,i i , n , j l l l l l

~J.r to Cold Box(lb mol/hr)

210,7332,509

56,548269,790

m

269,7907,813,640

8495

Componentwu

N202A rTotal d ry, lb mol/brH 2 0Total wet, ib mol/hrTotal, Ib/hrPressure, psiaTemperature, F

Product Streams

(molX)

Oxygen toGasLficat ion( i b m o l lh r ) ( m o l X )

m

54,968.8276.2

i u,

55,245.0m

55,245.01,770,030

1,115201

78.110.93

20.96100.00

Nitrogen(Ib mol/hr) (mol~)

- 23,470.6 100.0099.50 0.2 Max. 10 ppmv

0.5 0 1.2 50 ppmv100.00 23,472.0 100.00

23,472.0657,600

2290

IT-1.2.6-3

- - r


26/115

Atmo sp h e r i c a l r , a f t e r p a ss i n g th r o ug h an in l e t a l r f 1 1 te r ,i s c o m p r e s s e d i n t h e a l r c o m p r e s s o r . F o l l o w l n g c o m p r e s s i o n , t h e a i r i sco ole d In d lr ec t- co nt act Water Wash Tower 22-01-1203. The cooled compresseda i r t he n e n t e r s t h e c o l d b o x, a n e n c l o s e d s t e e l s t r u c t u r e c o n t a i n i n gc r y o g en ic equ ipment f i l l e d w ,t th in su la t in g ma te r i a l . The a i r en te r ~ th r ou g h as e t o f a u t o m a t i c s w i t c h i n g v a l v e s t h a t c o n t r o l s t h e f l o w t o R e v e rs i n gEx ch an g v r 2 2 - 0 | - 1 3 0 6 , Th e r ev e r s in g ex ch an g e r I s an a ssem b ly o b r azedaluminum, extended surface hea t ex ch an g e r s t h a t h av e th e d u a l f u n c t i o n o fco o l ln g th e a i r and r emo v in g wa te r and ca r b o n d lo x ld e f ro m i t at the samet i m e . The alr t u cooled by heat exchange wl th ou t1owlng gaseous p rodu cts andwas te n l t r o g c v . The p assag es ar e a r r an g ed so th a t s t p r ed e te r min ed in t e r v a l sthe a i r and waste n i t roge n s t reams a re swl tched by oper a t i on of the va l ves a tthe warm end , wi t h th e ch eck val ves cont ro l l in g the f lows sc the co ld end .When the a i r i s co o led , the conta i ned moisture i s condensed as water and ic e ,and th e ca r b o n d io x id e i s d ep o s i t ed a s s so l id a t l o ~e r t emp er a tu r e s . Whent h e a i r a nd w a s t e n t t r o g e n p a s s a g e s a r e s w i t c h e d o ve r , t h e d e p o s i t s e r eevap ora t ed in to t he ven t s t ream in one se t o f passages and car r ie d ou t o f thesy st em wh i l e th e imp u r i t i e s f r o m th e a i r a r e d ep o s i t e d in th e o th e r se t .S in ce e l l t h e p assag es a r e in th e r ma l co n tac t w i th each o th e r and ~rl th th ep r o d u c t s , t h e r e i s co n t in u o u s h ea t ex chan g e.

Th e co o led a l r , n o v a t ab o u t - 2 8 0 F an d c lo se to I t s d ewpoin t , i s se n t to the bo t tom of High-P ressu re Column 22-01-1 202 as fee d . Thep r ln c l p a l f u n c t io n o f th i s co lu mn i s t o p r o v ld e p u re n i t r o g e n a t t h e to p a sprodu ct , impure l iq u id n i t roge n as ref lux for Low-Pressure Column 22-0 1-12 01 ,an d a l i q u id r l ch in o x y g en a t t h e b o t to m as f eed f o r th e lo w- p r ess u r eco lumn. Re1ux or ~he h ig h-pr ess ure co lumn is p rov ide d by Hath Vapo r iz er22-0 1-1 310 , which by vap or iz ing l iq u id oxygen In the sump of the low-p ress ureco lumn, condenses n i t roge n r is ing f rom below.

i

R ich l iq u id f r o m th e su mp o th e h lg h - p r e ssu r e co lu mn I sw i t h d r a w n a n d p a s s e d t h r o u g h e i t h e r R i c h L 1 q u l d F i l t e r 2 2 - 0 1 - 2 2 0 3 o r22-0 1-22 04 . These 1 l ters , f l l led ~rl th ads orbe nt , s erve to remove the bu lk ofan y h y d r o ca r b o n s t h a t en te r w l th th e a l r and a r e n o t d ep o s i t ed I n th er e v e r s i n g e x c h a n g e r . F o l l o w l n g t h e f l l t e r s , t h e r l c h l l q u l d i s s u h co o l ed I n

II- I.2.6-4


27/115

C Aux il i a ry Vap ori zer 22-01-1308 by vapor i z ing lSquid oxygen and then expandedin to the low-pres sure co lumn a s f eed . The low-p re s sur e co lumn ope ra te s a tabout 19 pa l a , wit h bo i l -u p f rom the main vapor izer and r ich l iq ui d feed andimpure l iquid ni t rogen ref lux f ro~ the h~gh-pressure column.

(

Pure oxygen Ls produced a t the bo t tom of the lo w-pre s sur ec o l u mn . As a s a f e t y p r e c a u t i o n , p a r t o f t h e l ! q u l d i s c i r c u l a t e d v i athe rmo s lph on ac t ion in the au xi l i a ry vapor ize r th rough L iquid Oxygen F i l t e r22-01-.2202, whic h i o similar to the rich liquid filters. Ano th er part of thel l q u l d o x y g e n w i l l b e w i t h d r a w n t o O x y g e n V a p o r i z e r 2 2 - 0 1- 1 3 1 1, w h e r e i t i spar t ia l ly evapora ted to give a gaseous oxygen product . The gaseous produ ct iswi th dr aw n overhead from Separator 22-01-1204, while excess liquid is returnedt o t h e s u m p o f t h e l o w - p re s s u r e c o l u m n b y e i t h e r O x y g e n P u m p 2 2 - 0 1 - 1 5 0 3 o r2 2 - 0 1 - 1 5 0 4 . I n o r d e r t o e v a p o r a t e t he l i q u i d o x y g e n, a s t r e a m o f g as h av i n ge s s e n t i a l l y t h e s am e c o m p o s i t i o n a s a ir ' i s t a k e n f r o m t h e h i g h - p r e s s u r ecolumn , con den sed , and then fed back to the column. Par~ c thi s condensedair is withdrawn again f rom the column and used as ad di t ion a l re f lux in thelow-pressure column.

G a s e o u s w a s t e n i t r o g e n i s p r o d u c e d a t t h e t o p o f t h elow-pre s sure co lumn. This i s used in Subc oole r 22-01-1309 to subcool thel iqu id n i t ro gen produ c t and re f lu x s t r eam s ~nd ~he l iqu id a i r r e f lu x . Thewaste is be warmed fur the r by cond ensin g a small a i r e t r eam and by the pureg a s e o u s n i t r o g e n p r o d u c t b e f o r e i t p ~ s s e s o u t t h r o u g h t h e r e v e r s i n gexchanger , removing the deposi t ed water and carbon dio xid e as St is f in a l l ywarmed to a mbient tem per a tu re and exhausted through a s i l enc er . The gaseousoxygen and n i t rogen produc t s ~ lso f low out th rough the r eve r s ing ezehan ge r ,leav ing a t ambient tempera tu re , rea dy for compress ion.

|

4

In orde r to ma in ta in the cor rec t t empera tu re s th ro ugho ut thec o l d b o x , i t i s n e c e s s a r y t o p r o d u c e r e f r i g e r a t i o n a t a l o w - t e m p e r a t u r elev e l . This is achieved by taking some pure gaseous ni t rog en f rom the top oft h e h i g h - p r e s s u r e c o l u mn , r e h e a t i n g i t p a r t i a l l y i n t h e c o l d - r e v e r s i n gexchanger and then expanding i t in Turbine 22-01-1803. The turb ine is coup led

11-i,2.6-5

I Ii


28/115

t

t o o n e l e c t r i c g e n e r a t o r , a n d t h e g a s t e m p e ra t u r e w l ll be lowered by about70F while prod ucing power. It is be sent back through the s ub co ol er and ther ev eza ln g e x c h a n g e r as g a s e o u s n i t r o g e n p r o d u c t .

T h e p l a n t i s p r o v i d e d w i t h t h e m e a n s t o d i s p o s e o f p u r g e dl l q u l d s b y e v a p o r a t i o n , u s i n g w a r m c o m p r e s s e d a l r I n P u r g e S t a c k 2 2 - 0 1 - 14 0 1 .F o r d e r l m l n g a n d r e a c t i v a t i o n o f f i l t e r s , D e r l m e S y s t e m 2 2 - 0 1 - 2 8 0 3 w l t hR e g e n e r a t i o n H e a t e r 2 2 - 0 1 - 1 3 2 1 i s p r o v i d e d , a n d t he d r y a l r h e a t e d i nDef r o s t in ~ Heater 22-01-1312.

D. Risk Assessment

T h e g a s i f i c a t i o n u n i t r e q u i r e s a m a x i m u m of 24,600 stpd ofo x y g e n a t 1 , 10 0 p s lg . T e n o x y g en p l a n t s p r o v i d e t h l s ~ H i g h - p r e s s u r e o x y g e ng a s i s p r o v i d e d b y c o m p r e s s i n g t h e g a s e o u s o x y g e n f r o m t h e c o l d b o x i n t w os t ag e s. Th e c e n t r l f u g a l c om p r e s s o r c o m p r e s s e s o x y g e n t o a b o u t 6 1 0 p s i g a n dt b e r e c i p r o c a t i n g c o m p r e ss o r u o 1,100 pslg. The nitrogen gas required by theprocess units is provided by compres sing t he l o w - p r e s s u r e n i t r o g e n p r o d u c e dI n t h e c o l d b o x U s i n g t h i s a p p r o a c h , m o s t of t h e e q u i p m e n t r e m a i n s w i t h i nt h e l i m i t s o f c o m m e r c i a l l y p r o v e n t e c h n o l o g y . T h e r e c e n t l y c o m m i s s i o n e d3 x 1 , 0 0 0 s t pd o x y g e n f a c i l l t y n e a r H o u s t o n e m p l o y s t h i s c o m b i n a t i o n t oc o m p r e s s t h e o x y g e n o u t p u t t o 1 , 2 5 0 p s l g , t h e o n l y d i f f e r e n c e b e i n g t h ecapacity of the oxygen cnmpressors: 2,500 stpd vs 1,000 stpd.

The o xy gen su p p ly i s o f c r l t l c a l imp o r t an ce to th e g as l f l e r st o m a i n t a i n p l a n t o u t p u t , F o r t u n a t e l y , i n r e c e n t y e a r s t h e r e ha s b e enexcellent expsrlen ce wlth large oxygen plants. The design selected is si mil art o t h e s y s t e m o p e r a t e d s u c c e s s f u l l y a t S A S O L . Air c o m p r e s s o r a n d o x y g e nc o m p r e s s o r s e l e c t i o n s h a v e be e n i n f l u e n c e d s t r o n g l y b y c o m m e r c i a l e x p e r i e n c e .The ozy ge n plants at SASOL and this plant produce 2,500 stpd of oxyge n st 500p s l g a n d I , I 0 0 p s lg , r e s p e c t l v el y . T h e o x y g e n c o m p r e s s i o n f a c i l i t i e s a r e n o wdesigned and operat ed with a very high level of safety and rellablli~y.

I I - 1 .2 .6 -6


29/115

.r :i ! r ' ,J

T h e c o l d b o x , w i t h f e w m o v n g p a r e s an d 1 00 % i n s t a l l e ds p a r e s , c o n t r ib u t e d v e r y l i t t l e Co s h u t d o v n t i m e o f t h e p l a n t . W i th n o r m a la i r q u a l i t y , t h e r e a r e n o p r ob l em s o f c o r r o s i o n u s i n g t h e s p e c i f i e d a t a a d ar dm a t e r i a l s o f c o n s t r u c t i o n . A d e q ua te o x yg en c a p a c i t y i s i n c l u d e d t o a l l o w f o rf l e x i b l e o p e r a t i o n o f t h e g a s i f i e r s a nd m a i n t e n a n c e , d e r tm ~ a g , e t c .

CX I - 1 . 2 o 6 - 7


30/115

J

~ l ~ t f l m ~ l ~ s ~ r V ~ F ~ I I I I I I ~ r J 4 ~ 1 1 ~ I i ~ ~ I I ~ l 1 4 ~ l ~ r l l l ~ t f ~l ~ l q l ~ ~ ~ 1 ~ ,

I 1 [ I I I I I I I

Z . P r o c e s s , F l o w a n d C o n t r o l D i a g ra m - , ( I n c l u d i n g H a t e r i a l B a l a n c e )

P r o c e s s F l ow a n d C o n C r o l D i a g r a m s f o r O x y g e n P l a n t U n i t 2 2 a r ea s f o l l o w s :

D r a w i n ~ N o , T i t l e~ e

D - 2 2 - M P - I N PD - 2 2 - M P - 2 N PD - 2 2 - M P - 3 N PD - 2 2 - M P - 4 N PD - 2 2 - M P - S N PD - 2 2 - M P - ' 6 N P

P FC D O x y E e n P l a n t - U n i t 2 2 A i r C o m p r e s s i o nP FC D O x y g e n P l a n t - U n i t 2 2 C o l d B o xP C D O x y g e n P l a n t - U n i t 2 2 C o l d B o xP FC D O x y g e n P l a n t - O n i t 2 2 O x y g en C o m p r e s s i o nP F CD O x y g e n P ! a n t - U n i t 2 2 C om m on E q u i p m e n tP FC D O x y g e n P l a n t - U n i t 2 2 M a t e r i a l B a l a n c e

~ r

II-1.2.6-$


31/115

A

C

D

' I I , 2 ,, I : ~ l 4 . ,i i l l i i ~ .22-01-220S 22-0 i*130~ o ~ OA z ~ r .~ a ~ s s o ~ . AI R C ~R EsSO ~ ~ n ~ ' a E S S O ~AI~! f]TAKEFILT ER 2 m STAG ~ ~ l ~ -

$0"-AX-22AMBIENT

r SEALING I R / LEAKAGESEJd.IHGAIR/LEAKAGE

.~,-m-r~osSILEHCm

t i 2

0r- "

]2 Z ' - O l - l O 0 1 ,

TO ATHOS,

I ~ l - I ) O 2

~ " ] ~ C ' ~

~ ] - ~ CONO INSA'T .

22-.01-13030

0 -

Z2-Ol-tSOlAIR CO~RESS~

t I o5 ,~ led- lapf ; I ' ~ w l i :~ -e I q w u l I s oA l y . - ~ l I -~-_:,- , ,o, , , , o . F o , ~ l , y i o . , ~I a I

o ~ e l J I . ,p I , J . ' '" " - - ' i1 1 I G

I t U ~ ; I i t . , "4 t


32/115

' + . . . . . . . . " __ I I 'e e . o l - . o , t * ~ l ! z . ~ *

, o l c ~" - - Z J C c T o ~ " I . FO~ Om~ xnxmo ; , ~ ( ~ f t ( 1 ( , t n E N T l r ~ LTE AM CQH~RN~I[ R - - ~K ( F .GIJ IP M(NTSHOI+NOH Ti l ls I ) l tJVl /IO IS

. . . . . . T ~ | I I $ | H 1 H I S U H I T .

F .

[

l i2 2 - 0 1 - 1 ) 0 1

22, ,0 - I 80..._,,,.,.._.,~T

E , .

t l+2 2 - 0 i - 1 5 0 5~z-m-I~____~

P R E S S U R E C O X l R O L S I G N A L F R O M ~ D " 2 2 " 1 1 ~ ' 5 H P IH,P. I~'+G(N HF.kOEA

53 0 P$I6ST~M " D

2 2 " 0 1 - 2 6 0 515 o PSl; ~lr~M ~

COI~OEil~TE ~ E ~

[ ~ 3 2'-A -2 2

22-'01-1601 T 22-.01 IQ,.._,..___~SA m c o ~ E s s o n z z . -o t - is o ~xzn comaEssoe xur.em~CO~)ENSA'T PUMPS

OtlZPIt(NT ~0111( Oil TilL S OKJdrg(CJ22-0 ] - I ~K )1 22-01-160122-01-1302 22"01-11101T2Z"01-1303 22-01-2Z052Z-OI - I GOS 2 2 " 0 1 - 2 8 0 42~ '01-151~ 22-01-2605

92ZH P NP. g-',,#tI ~ , D E P A I T i " H E N T . O F ' E N E R G Yi e ~ r r V , ,q , G R A C E & C O ,t . - - - - . . - . . - - - ~ f , ~ . , , . ~ 1 5 e , e e e B . P . D .I L , C O A L , - T O - H E T H A N O L - T O - G A S O L I N E P L A N T. . . . . . . . . . ~ "V tt l I ~ ~ ' "

" ~ ' - ' ~ ' ~ I ~u "v . . . . | I J e , ~ , ~ I r o ~ m i x m c o u l, x ~s z m | D - 2 2 - M P - I H P I z ''~ .~6 ~ , I ' ' : " ~ 6 i

t l I1~1 I~ lqli N I I1~ IB~

A

Ii


33/115


34/115

. . . . . . . . . , , , ~ ~ ~ ~ l r , ~ , s n ~ , ~ : ~ , . . . . . . . . . . ...................................................................................................64 , _ . .. I o I 7

i i i i ! i i

, 2 - ' 0 t - 1 3 0 1 ~ ' Z - O l - 1 3 0 ~ li . t ,l ~ ( t a r . m r s , ~ o , m . . ~ , m s sto . o , ,~ , ~ m . 't.m~ ~ t,m m . t z ~ u

. . . . . m ~ m s z , r o s s u . z t.

* 1 + , 1

, : ~T2J

I+ . . ;

9 + e

Jm

r _ l - - i o- _

- - I - - + -

. - - - ~

i

- - , ( . . , , p . 3 ~ - ~ , ~ ' l

~. -o l -~ ,m~. - - ,

" , 4 . , - . . .. , : , o - 2 z - ~ ~ I

' t. _ . _ _ ~ _ , , / '~ '- " - ~ '

, . . . . . . . . . .,

' I t . , " ' ~ / / O X Y G E HG A ~

] I ( |' T R O G E ; r , M P A [ $ S O R

2 2 - 0 1 - ~ . 8 0 322"01-1804

Io ~ s ~ , ~ , ~ I I . . . . . . I4 4 1 '

E O U ~ U E H T S H OR N ~ T H I S 9 R A I I k ~2 Z = O l - t 2 0 3 2 Z - 0 1 - I I 0 32 Z - ' 0 1 - 1 3 0 5 2 2 - 0 1 - 1 8 0 (2 2 - 0 i - I ' ~ O T 2 Z " 0 I - Z 8 0 12 Z " 0 1 - 1 ~ 0 5

m

, _

m

D

I EO 2 : ' li ~ X P . O G A ]t - - " * " . L T D . I U . S , D E P A R T M E N T O F E N E R G Y/ ' ~ L . I 1 ~ ,. 4 ~ I - -, & a .u l m . m b ~ .j ,~ m j h m , , i~ m . , ~ l. ,g l j, m ~ d , A b X jq t t, j b S . ~ . l t c s. .. ,~ s , ,l ~ o R m G ~ I } d ~ E [ ~ 1 C O o K E N T U C K Y ," 1 5 9 , 0 0 0 o . r . o . I . I I ,~ 21 r'." ." ." ." .3 ~ | C O A L - 1 ' 0 - . H E T H A N O L - T O - G A S O L I N E P L A N T I

I I I P R O ~ $ S F L O W A N O C O N T R O D S . .~ . .t ~ ": ,~ t ( | t ~ N E I 2 B O 0 i E I 8 2 | tI I _ _ _ ~ I o x ~ . E , ~ m " - ~ m ; ' 2 z I ~ , - .' . ,- , ,. - ,, , ., , - ~ ' I / ~ II 1 1 . 1 R ~ N , r m s ~ s ~ I m o s o x E x ~ s I D - Z 2 - M P - 2 N P I ' ' -~ 1 ,t , i l p A ~ . ~ O ~ I 4 A .C ~.Z FO ~,~ Z , I . . . . . , , , , I , , * ~ . . . . . . . I J ~ - -


35/115

m

A

D

E

. . . . . . . . . . . . . . . . . . . . . , , , , ,~m~ ~,..~ ~,~~p,~'; L~~%d~'.~.~r,~cv."..~~s~ ~ z~' ~ ~ ~ ~ L ~ ~ % ~ ~ ~ ~ . , ~I : ' I a I, , 4 4 1 ,

" ~ A - ~ O X ~ , ', n [H A P O R I T I~ R , H IO H l t r s s ~ c o l . U ~ i 4 i 4 A X , V A P O ( tX Z I ~ I L b O l P H E ~ U f l C

I

i IL ~ , ~L - -

~ , _ . _ _ _ : : ~ ~ !i

- - - - a . . . . . . . . . . . . . . " 1 2 2 - 0 1 - 2 2 ~ ) 3I |_ . - . - - . - . - - . . , ~ -

i , o .~,~.

1 , - z 2 - ,P - 2 , P ; . . . . . . .

i i

I e ' 2 z , , ~ r - 2 N P )

< o - z z - w - z ~ - I

e

~ - 0 " 2 2 - k I ~ 2 I { P J . .. .o - 2 2 . ~ , 2 ~ i - - "

t - _ _ _ _ _ _

2 2 - 0 t - I ]1 1 - ~ [ 2 2 - 0 1 - 1 2 0 4

I

1~ ,~ . -~2 2 - 0 1 - 2 8 0 1O X Y G E N P L A K T C O L O B O X

2 2 - 0 1 - 1 5 ~2 2 ~ 1 - 1 5 0 4C O LD ~ X L ~

N

I c l ~ c v ~ l 1 , u "l s x ~ " e s ~ . _ - . .I B l ~ q ] S O l ~ ~A l S t v o f f I I n X ' _ _ 1 ; 7, ~ l - , , ~ , I ~ 1 ~ 1 , , , . ~ , ~ . .' d , 4 k


36/115

, 1 ~ ~ 1 | - 0 1 - 2 1 0 3 e Z lO4 ~ I I -01-1401

~ -22022 2 - 0 1 - 2 2 0 4

+1

2 Z - 0 1 - 1 3 1 2

I--'~ 1 = OEFROSTIHG IR (

:t Z- O l- 14o____~

/t

1

II

I A L E . & C . L T D .~xa _. +._~,:, . ._.~.. .--+L~... ,d~kLNdl.S.

- !+ - m - ~ + . " " " ! I, P e- ~Cl lREPORT I . . . . I , , '

I , ~ - ~ m ,m z m l l ' . ; . .. - ,= , . , . , l ~ m . , m . . m m c m o : ~, m m ,. ~ i+ + , m I ' ; " " " " ' I II J R - - e , 4 ~ , C~.X[~l~]~

I 7 _ _

S TE AM ~ I - ' - i

r a P , , < o - : , z ~ - ,P II ) I~ STSTmaO~ENSAT( ~ I ~

D2ZMP3KP.OGA

HOTE~I. THE (OI~ I~H T SIIMIfl OH THIS OAAh'TliO $POA OME11~11 IHEREARE T t3i |OEHTZCAL,TRt]HS N TIQS UI(ZT.

rQUIPMEHTSHOIINOH TH|5 D~I (G z22- 01- 1201 22- 01- 22022 2 - 0 1 - 1 2 0 2 2 2 " 0 1 - 2 2 0 322- ' 01 - 1204 2Z - ' 01 - 220~22- 01- 1~J8 2Z" 01- 28012 2 " 0 1 - 1 3 1 02 2 - 0 1 - 1 3 1 !2 2 " 0 1 - 1 ) 1 222- ' 01 - 14012 2 - 0 1 - 1 5 0 32 2 - 0 1 - 1 5 0 4

U. S. DP..~d~t~RTHENT OF ENE RG YW J ~ G W C E & C O . K ~ ' ru o o r5 g . g l ~ B . P . D .C OA L - T O - H E T H A N OL - T O - G~OLINE PLANT

. x m m . o , A m) c o m m o ~ m , , I , o ,E j , o o / r o B 2 I0 r a m P L ~ - u ~ ~z l~.,,.,,,,.,Jf i 1 , ~- ~ = 1 0 - 2 2 - + 9 NP I , ~ ,

A

r


37/115

o(

A

4,c

D

,, ,, , I . . . . . . . . . . . . . . i , , , + I ' + , + .m - , .i u - ' ~ * + r - - . - o , - . , + * ~ t "_ ~ , u n E ~ O I L~ S T H . O X Y i ~ L T E f l . C O M ~i~ ES SO II L , ~ O I I| N TE R C O O L E R A F T ( f l C O O L E R - - ~ . :

I , I22-01-2B02

I ~ I HS O P S |O $ T ~t ll

t e , - z ~ , - .u r - 2 s P . , - ~ - ~ r 'x '2 +OXYGEN/COLD OX

F--] lUTUOG(N

ATII

" 1 ~ ' - - - I II

' i

SHIJTOOVI(T 2F . 'OI l l l02T

III

Fo

1 - 7 ~ 1 ) p s l o S TE AM~ ' l~ . S Z - la ~ , - T N P i 1 5 0 P $ i G 5 1 1 4 1 1 / i 5 0 P S T G S T E X H K O D R U

I

I :

9

"I D

22.01=1314 ~,IPIL

r

22-OI- IOOZTOXYCEN o~a+n~soRI U R g , . t ~

F + I _ a . .I

~ . l ~ i l r r l O N D A A W I N G N O , [ ) ( $ I I I P T I O N ~ R I I1 l P J : I . I I N T O l S C I t l l r T l O ~ l I = I 3

0 s-l,+++Q g C ~ ' a ~ tA ! V i V I U

N O , D A T E I ~ L N O . * D A T I :

d _ + L ~ k d , ~ . . . p , r " ~ ] . . . . .SO P, l .GS --~-. ,

I R#,~ GS . ..I 4 ' + '


38/115

4 , R _ _ it t - O l - 1 3 1 9 4 P~ cmeaEs.~, tAFIERCQQLEIt

i

I D - . , ^rj IiII

- - l

,%

, ' .r 22-01-1315 l. m . . ,

V ' , , - O l - I 3 , . e

, . , , . ,. . . . , - ,

I

' ' ) 1V

u

.=2-oHoo=OX'YGEN~RE,SSOR

i ~ ' m T ~ m m o m T | ~ ' - ' ,o n u . x ~ r A P e e 0 v ~ , , i . . . . . ~ !~ m E , . =.E,Z~ I - 0 " - = ., - -- ~ + q f l i t O N I I a m v o e l . m i n t

I

0 I . . . . . . ' t, m

III

IlIIII-_2

2 2 " 0 1 - 1 3 1 9 e

I l I E I ~ 14. P ~ C I ~p A S A D ~ , C A L I F C ~ I t A

s I

m

HOTE,~h TII~ OUZPMEIITSHONHOH THIS DRA~NG $F ~ ONE InAIH . THE ft( AH( TEJI DEI(TZCALTRAZH$ N THIS UHIT.2, 5P[[O ~CHEA$IHGGEAR it}X,

u o ' - o D - 2 ~OXYGE~tIp OXYG[I< IP..4DER D-22 "MP - fl r~

[OUTPMENTSHO'JHDN TiP~ DP.,k~HGa22-01-1205 22"01-18022 2 - ' 0 1 - 1 3 1 4 2 2 - ' O t - 1 8 0 2 T2'+*01-1316 22-'01-1805;12-01-i317 22-01-220122-01-1319 22-01-280222-01-13Z0

022HP4NP.DGAi U . S . D E P P - ,R T H E N T O F E N E R G Y

.... C O A L - T O - M E I I - L ' 4 N OL - T O - G A S O L I N E P L A N I

OXYGENpLANT - UNiT 22 I,,o:,+.,~,,,~+. I I ] ~OXVnEHC0m'eE Sm 0H , | D - 2 2 - M P - 4 N P I / - ' ~e t

7q

i


39/115

m i

A

m

B

, 4 ,c

m

D

E

1

I ' i ~ i " R ' J I 4 E N T AL ~WATEHWASH OWER

I 2i r a , _12 .01 . I ) z IA l ~2~ l t - 2~sm~ - o l - i ~T z ~

,YE A- cooL{~s

I i iZ3-OI,,.~aOT22-04-280P

T~ IN s ~d",,,ot)-zz

I IRAIN4 ~ " 0D-22L UN[T 2 I _TP4IH $ J, ~'-.00-22

I UHIT 22TRAIN Z ~t~ n-Z ;~

UNIT 22 I0-22-HP "2 HP ID-22-11P-'~NP "~ ,/ O LO BOX NSTRUMENT DEFROSTING ]R0-22-U ~-4 HP !--(}XYG~H/up OXYGEN~RES SOR IO'..DD-22

$

FII

I iI O ' - . D O - 2 ! _ I 2 Z - 0 5 - 1 8 0 8 1 0 " , , ,0 0 - 2 2r - ~ ' l 2 z - o s -3 2 . ~ _ _ _ [ ~IllII

10"-00-22

10",-U0-22i,,.. ~. 3~-0~-1321

t

I m . - , - T . = . ~ ~ m b ~ N I22-01-1905 < > II O" 'DD'22 ~ iI - ~ - ~ ,--~SHUYDBWN

~-ol-i~-'~-~

L---.---T~oR$15 'YP]CALEACHOF I0I R~IROCATIHGI COi4PRESSORSL

J 2 Z - 0 1 - 2 8 ~ 0 2LLOI-2BO?O

IIIIIIItII

~

22-01-1805~,-o2-10o.522-0.,3-18~22-04-180~22-05-1805H,P. OXYGEIICO~PRSSORS

1 II I I I J l I I I I I I I '! I ~ I ' / - ~ 1 c l ~ ; v d I s o q ' n n l ' ~ l _ , -

2 I 3 I , 4 v


40/115

. . . . . . . . . . . . . . II I , - I I I - I I

rII

II

II

L,i

I

m~ j . v

~EHT . - .

t

' ~ I ~'~ STEAM' - - i 2 2 -0 1 -2 0 0 3

I

C O H D E N ~ [ ~

I . 1 ; 1 (E ~ H T S H O IIH H 1 ~S E I ~ : T ~ F O I lFIVE TRAiIIS. Ill [RE ARE I0 RECIPROCATJHoCIGUPRESSOfS H I0 TRA1H$ H OXYG(I~ PLAN TU N I T I Z ,l, TII[A ~ ARE ~ bLr;iFtld[ YS TI~5 , ONE IiiMODULE el (SERVING;MOOUL(S |k eZ) AHOOWE LOCATED N MOOUL[o3ISERVI~OMODULE~ Ae3 k e41,

24'-DD-22OXYGENGAS/eASiFIERS I O-2 1"~- ,I H P ~ >

VEto1

I + i ~ - ' ~ ; E r a . m , o ~ , I k ~ . ' . : - ,"~ ! E " . ' . ' ~ # ' ~ - - I I v ' ' . . . . . I

' " " ' " " " " / I . . . . . . . I4 , 4 ~ I . j , , m m , ~ . m . .i m m , A

(OUIPMEMT SH Ot~ Off ~ DP,~I];~Gz22'-91-1321A 22-01-280322-01-13216 22-01-280G22-02-1321A 22-02-2601;22"02-1"t218 22-03-28=G22-{)3-1321A 22-O4-2601;22-O3-1:3219 22-0S-280622"04-13~ A 22-01-280722-04-1)21B 22--02-260?22-05-1321A 22. '03-28072Z-0~-13216 22-04-200T22-01-i805 22-05-280722"0"Z-180522-03-180522-04-fa0522--05-1eo5

0221,1PSXP.G Ar L U . S . D E P A R T M E N T O F E N E R G Yi e A S ~ T V I I . G R A ~ & C O , ~ u c ~5 9 , 0 0 9 B , P , O ,C O A L - T O - M E T H A N O L - T O - G A S O L I N E P L A N T

D

Sm

I + ' * - - + + o +OXTGEH PLANT - UNIT 22,,, ~o , m ~ ( . T |'D~ '-22""P-5 P l'--t


41/115

A

ec

D

, i i i H ~H I i i Y

CO~OHEHTHOL ~IGHT.H 2 2O.OZk " 39,14

. o 2 : ~ . o o.,~GTAL FLOW~ L IIIFJr~III

A~IEItT AIR IHTAX(L6 HOUI'.R uOL X2 I t I ) 25. ' t ? l , I IZ61,05 0o9,~IS 893. SO 20, 9G29~0T0,50 I00 , O0~'O,96LB/HR el2 , 9'1'0IO/SCFD 255 , G6P~.~,"RE PSIA 14 . 3.... FJdP[RATURE F 80

~IA LO~EStB uOL/HR MOL820, 20 78. I I9. 6G O. 9'1222. 24 20, 96I , 05 (~ .30 IO0 ,O028. 9630, 708'

9.G6

Z f l S I ~ H T A IRLO UOL/HR I~)l. ll~4 , )T T I I . I IO. 29 0 . 9 )G.54 20 .9611 .20 100 . 0028. 96

so~O. 286090

PROCESS AIRLO,MOOJH~ i UO L~'2 Ii, pt. :SO T8, I250 .00 0 .935~6';4 . O s - 2,(1. ~,

26, 979_1 I 0 1 028 . 96, J J q ~~ .'N;k95

OXYGEN0AS TOOXyOEH OI~RES~ORLO MOL ./lai MOL 1(o . 0 0 . 0 137 .GZ 0 .50 :S , 4 9 G.08 99 .508 ,524 .50 I00 . 0932 .04177,00 450.:)Z

22

GkSE~JS XTRO~EH

o . I Z l : : '- " , " "o . 0 ~ I t O r ~z , ~ . ~ O l t ~ . . o o! .28,0~' I~ s , m - , i 4,21.'~R iZ . . . .

. . . . . . i

i _ ~ _' ~ L' ~ . I l l | l l I i l l ' I I 3

. - Ij J . I - ,II.L,,JW....,,.I " l . ~I -~ ", ,' q I m ~ , . I I ' G S l - ~. .: :I I " ~ ' l ~ ' = I r , ' I ~ , ~ ~ - ' - ' ~"


42/115

. . . .. . . . - " - - 1

. , . . . ~ , a ~ r u

I00.00

2Z9O

~CE, To a~ x~ s W,STr mTeO,~L - - ~ " I l O L Y L D U O L /H R U O L Z0,0= 0,0 IBr 72-' i. IS 90.0021,69 0 .50 2Z3. 5G I . IT5e 495.09 ! _99.55 159.59 0 ,8351524,50 IO R,OR 19 lOT,]tO iO0,O032.04 . 28. 19I TTr 004 536~ SOl50. 39' IT4.0 2h 115 ,, 14.?201 gO

' I I . . . t j= l q i l l l m.~ , ,,.. , . , , , . ,~ .U L ' F ,IIS, I~ CAIL,IF 'CI~IIt. . . . . . . . . . . . - - i,~ 1 L a / I I I . ill

l

, 1 7i , , ,XOTr~I , IHE MATERIAL BALANCE 5H0111 O~ l l l IS 5P, ~INO IS FOR ONE OF TEll IIIAIH5 A.~DFORfloRUA t. OPERAT][OR.2, THERE At4ETHREE ~AIHS IN HOUE5 el AHD=:ll AND ~ TRAINS N MOD~.ES =2 AHO m4.

AAIR LOSSES.~/se~. OCCURBEllEEH lit,IHTAKE AND COLD OOX, (STREAM%'/Z % IS HOTINDICATED ON THE P FCI~ ).

D2~II4~RP, OCAt U . S . D E P P .R T M E N T O F E N E R G Y

e,~sxe'rr W,R ,I~AAC E & CO, 'KEmUCKV5 B . B M B . P . D .COAL - T O - H E T H A N O L - T O - G A S O L I N E P L P JT i"

O x Y o ~ . P L AR T U m T 2 2 I = , ~ , = . , . , - - . J ~|a T E m L ~ U ~ E / D - 2 2 - M P - 6 N P I ~ u ' ~

D

6m


43/115

I

! r ' .

IT I

P . P l o t P l a n / G e n e r a l A r r a n g e m e n t D r a w i n g s

P l o t P l a n / G e n e r a l A r r a n g e m e n t D r a w i n g s f o r O x y g e n P l a n t U n i t 2 2a r e a s f o l l o w s :

D r a w l n ~ N o . Tltl__._.ee

D-22-PD-INP P l o t P l a n - U n i t 2 2 O x y g e n P l a n t

D - ~ 2 - P D - 2 N P P l o t P l a n - . U n i t 2 2 O x y g e n P l a n t

D-22-PD-3NP

D-22-PD-4~P

P l o t P l a n - U n i t s 2 2 a n d 5 1 O x y g e n a n d N i t r o g e nC o m p r e s s i o n

~ t i o n - U n i t 2 2 O x y g e n P l a n t

m

C1 1 - 1 . 2 . G - 9


44/115

p

, , . . . . . . . . : ~ , . , . ~ ~ , ~ J ~ ' ~ { ~ - ~ . L ~ ' ~ { .~ . ~ , ~ . ~ ~ , ~ , ' . , ~ ~ , .~ . " ,~ . '~ . ,,, ~ .. , , ~ , % , [~ '~ , . ~ : , ,~ , ,~ , ~ . ~ r z ~ , ~ , ~

,I tc ~

,Q, ,, p , , . = . m ., ,~ , , , ~ N O A O ~ W I A ' I ' G b l L . I N n . , I ~ , t , 4 . / 2 , O k O,

11 l {' . ~ g g . . o ' Z - ' Z ~ , ~[ / . . . - . . . ~1 - 7 , - - . F T - F - ~ , . . [ ~ !I I I ~ - , ,i _ _ L L? i i

I I

g g . . O l - I l~ o ' Z - '

~ . ~ ,. , ~ : ~

i - . . _ R Im

\

m

~ e 2 . - + L 1 ~ o ' 2

I t!I i . . . . . 1 _ . . .?( ' r ,~P)

I I l m I

' - -2/ . . . . . . . I

. i Im - -- - - - - ~

I

i! I ,m w . . . I

- - 1 . , ' Z .O Z . '~ ~ - . ~ 5 . /

! !D I ~ A W I N G N O . ~ , * _ -: . -_ = u - u ~ 0 1 1 A W I N G 1 1 0 ~ . ~ . ~ ;~ l r r I O N N O . i O A T . . . . . .I l y ~ H ~ i x ( : P R I ,I P . I. I [N 1 l I B (

\I.

i ~ . ~ ! : : l, L ~ ! . . J ~ . : ; i' ., I , i 2 .F o s e~ : g ; ~ .


45/115

1 - - ' - - q i I

~,~ _ , ,I' ~ , ~ ; ' " 4 , , - ~ I O I 7

, i

l l m m m ~ e em m I _ ii

I @i : "~ 1 ~ ' ' " l ~' (

I 2 :L ' [ ' i ; / \ -!

,-,,----t

\

I!I

i 1 1iI I i

I

L _ . _ _ _

Vl

i

= , ,

- ~ , ~ R _ ~ T ~ -' m I I ~ l ] , I ' ~ '~ . , ~" ~ S ~ PASADEN&CAUFORNIA

4 ~ . I ~ .I

0 , ~. * o t . I I ~ O l

t t ~ . - O l - I ~ O l Tl l C g . O t - g 6 0 ~" A * ~ . * : ' 1 - I ~ O Bl l ', / . '~.- OI . I D G W ' ~ - 0 1 - 2 2 0 5

, ~ < ;, u , ~ , ; F T . . , . U ~ "ML 2 2 - o | - I ~ : ) ~ A t lR C O I ~ I P R I 6 ' B O R ' ~ t~ ' B T / ~ i I / d ' l l I R G i ~ L I l lN 2~oI- , ~ m t A ~ R ~ M ~ I ~ 5 1 , T , I ~ 3 ; l l l l I R c o o i . l l R

A I R C O M P R G ~ ) ~ O R " ru R I ~I N ,% 6 T F . A . w l ~ N D E N ' ~ I ~ RA I R C O k 4 P R I3 .. .~ O R T U R ~ I N r l C O I 4O E ; t* d '~ g R B J E G ' I ' O I ~C O N O R N ~ 6, 'r n'. P U M PC D N D ~ N E k T G P U M P ~ b P , ~ R P .A I R I N ~ A K B F I L T E R

* 1 * ~* Z*O l . I~1 1 ~ L .R C.0 M p Jr .E "~


46/115

I l l ' I ! 4~ f *

i ~ " ' ' ~, . ~ .~ 4~ " ~ ' ~ 5 1 4 o l

' i F -

" - - i ' I- o

D

, lH

IIt q

V-I

I \

m

1 I~. ~ .~.~ ~ J

I

m1

I D O l .

~ m c~

\IR ~ ~ tv~T~.H 6,"~ ~ . C * o T O L o w

a I~ S C N I P T N

m l L m

I ll . . . . . . * ,

,1

~ b I , ~ , 4 D , ~ 4' ~ "b A i l ~ ~ I s c c m o J I c u ~ 'n


47/115

' , , , ,

'I

' i im

, r , , 1 , . , I

' ' , l ~ , . .n m ~ m ~ , ~ , , , , .- , ,- , . ' - ~ ' - ~ ~ , , ~ , ' ; , , , , , ~ ,~ .~

~I! ~ *'''' ! , -~ . . . . I~ , ~ / , ; , ,

I I I I I I I I

7i

- 1

I I~ 1 . , , l ~ : ; n m o ~ I I , . . v . c u p , , r I I ; , " ) ~ I . , ~ t K " , l l P A I IA h E N A . C A L I F O R N I ~ ,: 4 " ' I s I

N D ' I ' G ~ =

!1~ a ~ R r

U . S . D E P A R T M E N T d ' F E N E R G Y- ~ K ~ n " W , R , G R A C E & C O , X F . m ~ . K V

5 0 , 0 0 0 B . P . D .G O A L - T O - M ~ I ' H A N O L " T O - G A S O L I N E P L A N T

t i m i ' r " Z . ~ . ; ~ - - ' . , , , ~ - - / / ~ \

A


48/115

J - ' j ~ " i ~ i~ ! ! . .. . . .. . " h .

, I ~ i ~ 1 4 + '

A

B

m

- 0

m

~ , . . ,

iIi

m

D

E

f

~ . . " ' ~~ .I I I II i , I ! I

. l i

I ~ 1 . . i

~ ' ' ! o - ,

\

\ /. * ' o/ __~

_ / I

~ . ~ . o ~ - I ~ G

~ c : ~m m n n u m m ml U l ~ l n m n m l l l lm u l m n n m l n m mm m m m m m m m

m m m m m m mO E S C N t I r l l ~ IN

I ~ hi,. .,e~ ,~7 "~ ,~4a~ ... j ~._~_ ~ ,, :t '


49/115

i,r , , , : , ~ ~ ' ' , ...! , , ,

,'i' '

Io L _ # . . . . . . . . . . . .

1"! II i I I I I !I i I I I i , _ l

I f - - : . " ' ,I I !

J I J

,.! __ ..o!.,oo~..L .,o . . ~ . , ~ ...,L.,ooo5,~ .T TS,l~' I,.Ik'I1"II'~

i i

"~I - ~ , I ' ,t , ~ ~.~ l , O I , I I ~ O I

5 1 " O l . l ~ / ,

I I I . 0 1 - I ~ D ~

II ~ - , ~ 1 - I ~ I ,

~ I - ~ I . I ~ 0 2 ,

~ I - ~ I . I 0 " ~

~ , ~ I P ~ i R P . r I q ~ l I ' r l k R I q . l l e 3 i i

I ~ ' t ' l ~ O ~ . ~ , ~ A ~ I I I R ~ . O O I . I R

I ;F A ~ O U N L O A ~ N I ' I R ~ . t I

D

W / 2 2 " 0 1 - ' l B 0 * I .U e G O i l . ~ ' 6 " { I ~? . * Z . O l . ~ .l ~ ' / ' G O O L I N - L M & T I NGONI~Ot,3~ *IN~ -L1 J~t I~ t~I I' l '14C O l , 4 P R i ~ O I ~

~ c : n ' i , ~ ,I . A t . t . ~ Q V l P I ~ ' ~ ~ 4 ~ . 1 .I ~ t U k l l :J l l l ~ I I I L ' r I R s .

I I 9 1 m II I"

i,i

_ _ l R = m ; e ~_ ._ ,, ,~ .f f_ . : P ' . R a b , W D . ~ ! ~ " ~ J N , ' ' ' I I T H E R A L P H E L P A R $ O i l C O M P A N Y~ m ~ ,, ~ m ~ : m i = T l O N I t m i o ~ m ~ . | ~ R 1 4 ./ ~ I~ ~ p A S A D E N A . C A U F O R N I A

J

A

t c : ~ l U ; S . D E P A R T M E N T O F E N E R G Y~ E r r W . R . G R A C E & C O . ~ u ~ r5 0 , 0 0 0 B . R D .C O A L - T O - M E T H A N O L - T O - G A S O L I N E P L A N T,.~i p. ~. . i .cwu, ,T.um,~ p .~ . , ~ , . l, ,, ,~, ,m~p L o ' r p L ~ I P ' ~ L O ~ I " r a 4 1 i I Q ,a ~ . ',L r ., li 'r ' ~ 4 u ~ d l T m I - ~ . - . . . , . I I ~ ~ .


50/115

I I I 1 '1" , ~ ~ , 1 - - I ,. I . . . . . . . . J l U l l l*

. . . . . . . . , ~ ~ , . , ~ , ~ , , ~ . ~ = ~ ~ ~ : ~ ~ ~ ~ ? ` ~ ! ~ J ~ ~ . ~ . ~ ; ~ L ~ : ~ ` ~ : ~ ` ~ ~ ~ f , ~ ; ~ , ~ , ~ , ' ~ L , ~ ; ~ t ~ ,

iii i i i i i

0

I1 TI1~-# -~] I I

, . ~ 2 . 2 - O l - 1 ~ . o 3

1 ~ 2 , l i l ,l ~ k ~ l , ~ l , 1 1 ~ t I ~ ' 0 1 - I ~ 0 1

~ - ~ . -o 1 . , 2 8 o I

E L F . V ~ ' I I O ~ 4 ~ ' r O X , / < ~ F . ~ 4 ~ J T

C O L U t . ~ ~

A N DP ~ J ~ P ~

. ' Z ~ , o r . t

, ! _ L I I I ' I_ I I I .~ S

" ; 7 " i " : i " ; ; , 7 : r [ , . ~ 7 . a - - ~ , , , " F- ; ' : ' i " . - " ) ~ I ~ ' - - ' ~ . ' { i ' ] i : ' ~~ J . . . . . . . ! . . . . . . . . . . , ~ -. . -


51/115


52/115

i G . S i n g l e - L i n e D , ag ra mS i n g l e - L i n e D i ag ra m f o r O x y g e n P l a n e U n 4C 2 2 i o ~ o l l o ~ m :

D r g ~ n g N o . T i t l e

D - $ 1 - E E - 4 N P O n e-L & u e D i a g r a m - U n i t s 2 2 a n d 2 3

I I - 1 . 2 . 6 - 1 0


53/115

t l t ~ bm em~ ~ W ~

, A

ec

P

, I " I ~ I 4 _ , _ ~

J , h S K V $'I,$KV$ 1 - O . t r ~ l - t W I Tt . O X Y G E N P L A N ' I " /

TYP, FOR2 plACES15~ O/lftr JO I(YA TRI ~ 5 SlIOIr~ I~O011T;~$O ~VA3 4 . 4 K V - ~ IR . 71~I IO , rP . ~ ~ ,~ .,e 4 . 4 K V -4.1B IN t ' ~ ~'01.06-460~ ' Y% 4.16 KVZ'#X Z,aXI~011C'~'4603A ~2-Ol/O~#~OJB12."Z.

It:li i i . -

4#.~t~/~I'O{O~T

.-OZ'O4-4 .OZA I ~

j l 't M '4 1 6 0 V M C C I " ~ , ~ ,1 '" I

tu

o ~ ^ w , ~ N o ' .! ~ "~ .1 l l b 'M lI

lot, I ,:,,,i,,, j l fi 2

I I I i " ' i I I ~ Ji ~ l I I i / I i , LI~1 ~ i~ r m l ~r I F 4 ~ I ~ V I ~ ) , " . . .. ..l ~ : ~ ~ I ~ , ~ ' ;I ~ ~ - i ~ - J . , . [ , ~ " I . . : : : . : . . .ill d,,l


54/115

J' I .$KV$ 1 " I ~ T~0 . S HIFT /T~ , FOR # pL4Ce'SZ,t-OZ-4OI ~ I '00~/~$0 0 XV4

z.,~I , . , " " 1

1 ,1

3.~ I(V J #,$~' S l 'O l~ r ~L~ $1-OZO,tTL o , . , l

TYPo FOR I0 PIACFJ~- ' O t / I P#$O I - - 750 ~AIZ'OII lO-#fO$

~ _ 4 . z ~ o v . c c

/ T ~ , " I T ' = Z - S.T SXI _ _ ~ 2 2 "0 1 / H ~ 0 ~

N O T E S II . PRBItI~ 4Mw ~ ~'TER$ AT ALL LOC 4TI~ ~ 2, ~OVIDE $0 ~ RE lY TO 41.L ar)rORSJC/~D ~.

- ' I - U . $. D E P A R T M E N T O F F .N E R G Y ' ~ ~ I e ~ s K ~ ' r w . q . G R A C E & C O . K EN TU C KY

- I ~ ~ / 5 o . o o o . . R o .~ ; , , , . . _ - : ~ , o ~ - ! . ~ : : ' : . I " I ] ~ / . . . ~ O , L - 'r O ' M ~ " A N O ' 'T O " ~ A S O " 'N ~ " T~ ; ~ ~ ' ' ~ " ' ~ " . . . . . . I J , F o ~ , l ~ o , A c R = F 'N O N E I 4 ~ 0 0 ] , 8 2 1 _. . . . . - " _ ' ~ ? , ~ * 'we rwn , lL '= , - ,, , ,, , ,, , ,. I I I THE I IA i .PH M. PAR ON'= enM =, .=v I 9 J t' Y ~F N L A N T U ' 2 2 ~ - ' = " p . , . . . - . . . . I / , . ~, = ~ . . . . J I f ~ ] , , -o , . . . = , . .~ o , ~ ; z ' " ~ " S - . - i F T U N , T , , , L " * * / U - ~ - " " - ~ r l

A

J _

3


55/115

I l l I __ Il l

C , 1 . 2 . 7 CO SHIFT - UNIT 23T h e CO S h i f t U n i t p r o c e s s e s a b o u t 6 2 ~ o f t h e r aw s y n t h e s i s g a s

f ro m t h e c o a l g a s i f i c a t i o n u n i t o v e r a c o b a l t - m o l y b d e n u m c a t a l y s t b e d t oo b t a i n t h e r e q u i r e d H 2:C O r a t i o f o r t h e m e t h a n o l s y n t h e s i s u n i t a ndr e c o v e r s h e a t a s t h e g a s i f c o o l e d f o r u r t h e r d o w n s t r e a m p r o c e s s l n g . T h eb a l a n c e o f t h e r a w g a s i s d i v e r t e d t o a s e p a r a t e g a s c o o l l n ~ s y s t em , w h ic hr e c o v e r s h e a t t o p r o du c e s te a m .

A l a r g e a m o u n t o f h e a t i s a v a i l a b l e f r o m cooling shift reactoreffluent and unohlfted gas. An integrated heat recovery scheme is des ign ed tor e c o v e r u s e f u l e n e r g y fo r h e a t i n g s hi f t f ee d ga s , h l g h - p r e s s u r e b o i l e rf e e d w a t e r , p r o c e s s c o n d e n s a t e ~ a n d v ac uu m c o n d e n s a t e . P r o c e s s c o n d e n s a t e f r o mc o o l e d s h i f t e f f l u e n t a nd u n s h i f t e d g a s a r e r e h e a t e d a nd r e tu r n e d t o t h eg a s i f l c ~ t i o n u n i t .

A . B a s i s o f D e s i g n

T h e l a r g e q u a n t i t y o f s y n g a s f r o m t h e g a s l f l c a t l o n u n i tr e q u i r e s t h a t f o u r p a r a l l e l m o d u l e s , e a c h c o n t a i n i n g o n e s h l f t e d t r a i n a ndo n e u n s h i f t e d t r a i n , b e i n s t a l l e d . T he s p l i t o f s y n g a s i n t o s h i f t e d a ndu n s h i f t e d t r a i n r e s u l t s i n l o w e r c a p i t a l a n d o p e r a t i n g c o s t s f o r t h ed o w n s t r e a m A c i d G a s R e m o v a l U n i t . T he B a s i s o f D e s i g n n c l u d e s F e ed S tr e a m sa u d P r o d u c t S t r e am s ( s h o w n o n t h e g o l l o w l u g t w o p ~ E e s ) .

B . P r o c e ss , S e l e c t i o n R a t i o n a l e

T he r aw s y n g as r e c e i v e d f ro m t h e g a s i f i c a t i o n u a l t c o n s i s t sm a i n l y o f C O , H 2 , a n d C 0 2 , w l t ~ i s u l f u r p r e s e n t a s H 2S a n d C OS . T h ew a t e r / g a s s h i f t r e a c t S -o n c o n v e r t s CO a n d H 20 t o CO2 a n d H2 s o t h a t t h ed e s i r e d H 2:C O r a t i o i s o b t a i n e d t o f e e d t h e ~ o w n s t r e a m M e th a no l S y n t h e s i sU n l t .

I I - I , 2 . 7 - 1


56/115

i

I t m , I i , v e i ~ q @ ~ # 1 ~ ~ * ' t ~ H m I

Feed Streamsi i i ,

Component

H 2CH 4coCC2N2ArH2SCOS

Raw Shift Feed Gas Makeup Steam(Ib mol/hr) (mol%) (Ib mol/hr)

39,069.34 36.19214.41 0.2047,297.49 43.8119,221.42 17.81513.81 0 . 4 8172.46 0.161,374.19 1.2784.72 0.08

U n s h l f t e d G a s(ib mol/hr ) (molZ)

m

m

Tota l Dry, 107,947.84 100.00 -lb ~ol/hrH20 76,895.59 31,073.04Total Wet, 184,843.43 31,073.04lb mol/hrTota l, lb/ hr 3,711,910.00 559,800.00Pressure, psla 850 900T e m p o r a t u r e , F 435 640

2 3 , 5 1 1 , 6 4 3 6 . 1 9129.O3 0.2028,463.28 43.8111,567.31 17.81309.21 0.48103.78 q.16826.98 1.2750.99 0.0864,962.21 100.0046,275.17111,237.38

2,233,650.0085O435

Product Streams

C

ComponentShifted Efflueut

to AGR(lb mollhr) (molZ)Unshlfted Gas

to kGR(ib mol/h r) (molZ)Combined

Condensate( lb mol/hr)

H2CH4COCO2N2ArH2SCOSTotal Dry,lb mol/hrH20Total Wet,lb mol/hrTotal , lb/hrPressure, psiaTemperature, F

73,546.72 51.61214.41 0.1512,820.12 9.0053,771.42 37.73513.81 0.36172.46 0.121,446.82 1.0212.10 0.01

23,511.64 36.19129.03 0.2028,463.28 43.8111,567.31 17.81309.21 0.48103.78 0.16826.98 1.2750.99 0.08im

142,497.86 100.00 6~,962.22 100.00171.42 75.28 119,416.08142,669.28 65,037.48 119,416.08

2,951,690.00 1,4OI,320.00 2,151,400.00795 820 790100 100 223l l - I , 2 . 7 - 2


57/115

" , ' 7 - ' - " ". . . . j . . ~ _ I . . . . . .

, t , , , , i i , , i , _ , ,

6 i

E . T h e w a t e r / g a s s h i f t r e a c t i o n h a s b ee n u s e d Xn m an y c h e m l c a lp r o c e s s p l a n t s ; h o w e ve r , i n m o st a p p l i c a t i o n s , a n o n s u l f u r - t o l e r a n t c a t a l y s ti s u s e d t o t r e a t a s u l f u r - f r e e g a s . T h e s u l f u r c o n t e n t o f t h e r aw s y n ga sr e q u i r e s a s u l f u r - t o l e r a n t s h i f t c a t a l y s ~ ( e . g . , a c o b a l t - m o l y b d e n u m t y p e ) .The cata lyst man ufa ctu rer w-lth the most experience in sour gas shift Is BASFwi~h Its KS-If catalyst. The reactor is sized according to the BASF ca taly str e q u i r e m e n t . T h e r e s u l t i n g s h i ft se c t i o n is c a p a b l e o f o p e r a t i n g w lt hcatalyst from any of the other three vendors solicited for recommendations.

T h e s y s t e m i s d e s i g n e d f o r m ax im um u s e f u l r e c o v e r y o f ~ a s t eh e a t f ro m t h e s h i f t e d t r a i n an d u n s h i f t e d t r a i n . T h e u s e o f w a s t e h e a t f o rg e n e r a t i n g s t e am a nd h e a t i n g c o n d e n s a t e a nd b o i l e r f e e d w a t e r r e d u c e s t h e c o s to f p r o v i d in g g a s o l i n e .

The feed gas is split into shlfted and unshlfted streams toindividual acid gas absorbers to give the most eco nomi cal deslgn. The H2: C0rati o i n the feed to the Metha nol Synthesis Unit Is adjusted by varying thef] ~ of syngas to the shifted train.

D i r e c t s o u r s h l f t f o l l o w i n g g a s i f i c a t i o n i s s e l e c t e d o ve r as c he m e u s i n g s , ~ l f u r r e m o v a l , c o n v e n t ! o u a l h o t s h i f t f o l l o w e d b y CO 2r e m o v a l - P o s l ~ i o n i n g t h e c o n v e n t i o n a l h o t s h i f t b e tw e e n s u l f u r re m o va l a ndC O r e mo v al i n v o l v e s c o o l l n g a n d r e h e a t i n g t h e r a w g a s f r o m g a s l f l e a t l o nand thus will reduce the overall thermal eff.lclency of the Gasollne Plant .

C . P , r o ,c e s s D e s , c r i p t i o n

T h e e q u i p m e n t a r r a n g e m e n t a nd m a t e r i a l b a l a n c e f o r t h e COS h t g t - U n i t 2 3 i s p r e s e n t e d o n P r o c e s s F l o w a n d C o n t r o l D i a g r a m sD - 2 3 -M P - l '( ~ ,' , - 2 N P , a u d - 3 N P .

' , I

C1 I - 1 . 2 . 7 - 3


58/115

n ~ m

The purp ose of the CO Shi ft Unit is to sh if t earbou mouoxideand s team to ca rbon d iox ide and hydro gen in orde r to o b ta i n the r a t iorequi red for me thano l s yn th es i s . Appro xima te ly 62% of the r aw synga8 f romg a s i f i c a t i o n p a s s es t h r o u gh t h e s hi f t s e c t io n w h i l e t he r e m a i n d e r o f t h e r a wsynga8 is routed through the gas cooling section of the CO Shift Unit.

T h e p o r t i o n o f t h e r a w s y n g a s g o i n g t o th e s h i f t s e c t i o ni s m i x e d w i t h s u p e r h e a t e d m a k e u p s t e a m to o b t a in a st e a m t o d r y g as r a t io o fI : i. T h e s h i f t f e e d g a s is h e a t e d t o 6 0 0 ~ in S h i f t E f f l u e n t / F e e d H e a tE x c h a n g e r 2 3 - 0 1 - 1 3 0 1 a n d t h e n f l o w s t o S hi f t R e a c t o r 2 3 - 01 - 25 0 1. Ap p r ox i -m a t e l y 7 3% o f t h e

Documents

14759-T1, Vol 2, 14, Pages 122 - 236, 4.41 MB(material balance)