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Title: Advanced coal-gasification technical analyses. Project summary. Final report, December 1982-September 1985

Abstract

This report summarizes the work performed by KRSI to support the GRI Fossil Fuels Gasification Program in identification and development of the most economical and technically feasible process(es) for production of SNG from coal. The work was performed under several tasks that fall under three topical categories: (1) Technology Review and Evaluations, (2) Coal Fines Disposal and (3) Technical/Economic Evaluations. The final task reports appear in the three appendices of the report. The Technology Review studies provide an overview of the coal gasification, shift/methanation, acid-gas removal, and sulfur-recovery technologies for use in coal-to-SNG plant design; Side-by-side comparisons of selected processes in each category provide background for process selection. The studies relating to Coal Fines Disposal allow comparison and guidance with regard to feedstock-management options when fixed-bed gasifiers are to be used. The first-pass designs and cost estimates prepared under Technical/Economic Evaluations compare and assess North Dakota lignite-to-SNG plants based on Lurgi, Westinghouse (now KRW) and Direct Methanation processes. A plant size vs. cost study provides an insight to selection of an economical plant size.

Authors:
; ; ;
Publication Date:
Research Org.:
Kellogg Rust Synfuels, Inc., Houston, TX (USA)
OSTI Identifier:
5519733
Alternate Identifier(s):
OSTI ID: 5519733
Report Number(s):
PB-86-203130/XAB
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; COAL GASIFICATION; ECONOMIC ANALYSIS; TECHNOLOGY ASSESSMENT; HIGH BTU GAS; PRODUCTION; BI-GAS PROCESS; COAL FINES; HYGAS PROCESS; METHANATION; PROCESS DEVELOPMENT UNITS; RESEARCH PROGRAMS; SHIFT PROCESSES; WESTINGHOUSE GASIFICATION PROCESS; CHEMICAL REACTIONS; ECONOMICS; FLUIDS; FUEL GAS; FUELS; FUNCTIONAL MODELS; GAS FUELS; GASES; GASIFICATION; SNG PROCESSES; THERMOCHEMICAL PROCESSES 010404* -- Coal, Lignite, & Peat-- Gasification

Citation Formats

Cover, A.E., Hubbard, D.A., Jain, S.K., and Shah, K.V.. Advanced coal-gasification technical analyses. Project summary. Final report, December 1982-September 1985. United States: N. p., 1986. Web.
Cover, A.E., Hubbard, D.A., Jain, S.K., & Shah, K.V.. Advanced coal-gasification technical analyses. Project summary. Final report, December 1982-September 1985. United States.
Cover, A.E., Hubbard, D.A., Jain, S.K., and Shah, K.V.. Wed . "Advanced coal-gasification technical analyses. Project summary. Final report, December 1982-September 1985". United States. doi:.
@article{osti_5519733,
title = {Advanced coal-gasification technical analyses. Project summary. Final report, December 1982-September 1985},
author = {Cover, A.E. and Hubbard, D.A. and Jain, S.K. and Shah, K.V.},
abstractNote = {This report summarizes the work performed by KRSI to support the GRI Fossil Fuels Gasification Program in identification and development of the most economical and technically feasible process(es) for production of SNG from coal. The work was performed under several tasks that fall under three topical categories: (1) Technology Review and Evaluations, (2) Coal Fines Disposal and (3) Technical/Economic Evaluations. The final task reports appear in the three appendices of the report. The Technology Review studies provide an overview of the coal gasification, shift/methanation, acid-gas removal, and sulfur-recovery technologies for use in coal-to-SNG plant design; Side-by-side comparisons of selected processes in each category provide background for process selection. The studies relating to Coal Fines Disposal allow comparison and guidance with regard to feedstock-management options when fixed-bed gasifiers are to be used. The first-pass designs and cost estimates prepared under Technical/Economic Evaluations compare and assess North Dakota lignite-to-SNG plants based on Lurgi, Westinghouse (now KRW) and Direct Methanation processes. A plant size vs. cost study provides an insight to selection of an economical plant size.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Jan 01 00:00:00 EST 1986},
month = {Wed Jan 01 00:00:00 EST 1986}
}

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  • This report is a compilation of several studies conducted by KRSI under the Advanced Coal Gasification Technical Analyses contract with GRI. It addresses the issue of disposal and/or utilization of the coal fines that cannot be used as feedstock for fixed-bed (i.e. Lurgi) gasifiers. Specific items addressed are: (1) Technical, legal and economic aspects of fines burial, (2) Estimation of the premium for fines-free coal delivered to an SNG plant and resulting reduction in SNG production costs, (3) Comparison of the relative advantages and limitations of Winkler and GKT gasifiers to consuming fines, (4) Review of coal-size consist curves inmore » the GRI Guidelines to assess the fines content of ROM coals, (5) a first-pass design and cost estimate using GKT gasifiers in tandem with Lurgi gasifiers in an North Dakota lignite-to-SNG plant to consume full range of coal-size consist, (6) Evaluation of the General Electric technology for extrusion of coal fines and testing of the extrudates in a fixed-bed gasifier, and (7) Investigation of equipment and variables involved in briquetting of coal fines, such that fines could be fed to the gasifiers along with the lump coal.« less
  • This document is a result of KRSI's activities to support the GRI/Advisors Committee thru the duration of the contract. It provides an overview of the gasification, shift/methanation, acid-gas removal, and sulfur-recovery technologies for use in coal-to SNG plant design. For selected processes in each technology area, Status Summary reports are presented. The non-proprietary information contained in these reports was utilized to assess the characteristics, efficiencies, and other performance variables of each process relative to criteria developed for each ssess the characteristics, efficiencies and other performance variables of each process relative to criteria developed for each technology area. The results ofmore » the assessment are presented in tables that can be utilized for selection of a process best suited for a given application. In the coal-gasification area, status summaries were prepared for Lurgi, GKT, Texaco, BGC/Lurgi, Westinghouse (now KRW), Exxon CCG, Shell and U-Gas processes. The Conventional Shift/Methanation, Combined Shift/Methanation, Direct Methanation and Comflux Methanation processes were selected for review of shift/methanation technology. In the acid-gas-removal technology area, evaluation of Selexol, Rectisol, Benfield and CNG processes is presented. For the sulfur-recovery technology area, Claus, Amoco Direct Oxidation, LO-CAT, Selectox, Stretford and Unisulf processes, were selected for assessment.« less
  • This document contains the final report on four tasks performed by KRSI as part of the Advanced Coal Gasification Technical Analysis contract with GRI. It provides extensive, consistent technical and economic information regarding application of (1) Lurgi gasification, (2) Westinghouse (now KRW) gasification, and (3) Direct Methanation (with Lurgi gasifiers) processes to produce SNG from North Dakota lignite. The results of Lurgi and Westinghouse studies were used to develop a plant size vs. cost-of-SNG relationship. The report on each task consists of a block flow diagram, component material balance, process flow sheets showing operating conditions and principal equipment in eachmore » major process area, a narrative process description, utility balances, plant efficiency calculations, documentation of design and cost-estimation basis and an economic analysis performed in accordance with the GRI Guidelines. Economic analysis consisted of capital-cost breakdown according to plant areas, variable operating and maintenance costs, and calculation of levelized, constant-dollar cost-of-gas with and without process development allowances (PDA). The sensitivities of the gas cost to major variables are presented in graphical form. For the plant size vs. cost-of-SNG task, similar information is provided at eight different plant capacities based on both Lurgi or Westinghouse gasifiers.« less
  • Twelve techno-economic studies of coal-to-pipeline gas facilities were performed to identify the advantages and disadvantages of various processes. Realistic combinations of processes were investigated to quantify the overall efficiencies and economics. These studies address a variety of coal gasifiers as well as downstream processing concepts, including catalytic conversions and acid-gas removal. The report contains a summary of the results of each study, a comparison of the 1983 and 1986 FRI Guidelines, and a procedure for converting the levelized constant-dollar costs-of-gas based on one set of Guidelines to costs based on the other set of Guidelines.
  • The report summarizes the organics data from environmental assessments of several low- and medium-Btu coal-gasification processes conducted between 1977 and 1981 under the sponsorship of the US EPA. The data summary focuses on the concentration, composition, and mass flow of organics in the major streams of the various gasifier-related processes. Many compounds in the organics from the major gaseous-, aqueous, and solid-phase streams of the processes are identified. Organic compositions and stream concentrations among plants and plant streams are compared.