Startup and operation of the coal gasification section of a 1000 TE/day ammonia plant

Conference · Sun Feb 01 04:00:00 EST 1976 · Am. Chem. Soc., Div. Pet. Chem., Prepr.; (United States)

OSTI ID:5722413

Sharpe, R A

At the end of 1974 a 1000 metric ton/day coal-based ammonia plant was brought on stream at the AE and CI Modderfontein Factory near Johannesburg, South Africa. The process is based on the Koppers-Totzek low pressure, high temperature, coal gasification process. The feedstock is a semi-butuminous coal containing about 14% ash, 36% volatiles and 1% sulphur. Oxygen for the gasifiers is supplied from a single stream air separation unit. Coal dust is produced in two large ring and ball mills. The gas is compressed and desulphurized by washing with methanol at -36/sup 0/F (-38/sup 0/C) at a pressure of about 30 atmospheres. Desulphurized gas containing about 58% CO is reacted with steam over conventional iron high temperature shift catalyst to produce hydrogen. Carbon dioxide is removed from the gas by washing with methanol at -72/sup 0/F (-58/sup 0/C) at a pressure of about 51 atmospheres. Final gas purification to remove residual carbon monoxide, argon and methane is by washing with liquid nitrogen at -310/sup 0/F (-190/sup 0/C). Ammonia synthesis is at about 220 atmospheres in a conventional synthesis loop with ammonia refrigeration. The process units are all controlled from a central control room equipped with electronic instrumentation. The contract for the plant was placed in May 1972, and ammonia produced in December 1974. Availability of the six gasifiers installed has not always been satisfactory, due to the various problems described. However the major losses of production so far experienced have generally been due to failures in upstream or downstream units of the plant not associated with the gasification section. The six gasifiers installed are capable of achieving design plant output.

• Research Organization: AE and CI Ltd., Modderfontein, South Africa
• OSTI ID: 5722413
• Report Number(s): CONF-760458-P1
• Conference Information: Journal Name: Am. Chem. Soc., Div. Pet. Chem., Prepr.; (United States) Journal Volume: 21:1
• Country of Publication: United States
• Language: English

Related Subjects

01 COAL, LIGNITE, AND PEAT
010404* -- Coal
Lignite
& Peat-- Gasification
090320 -- Inorganic Hydrogen Compound Fuels-- Preparation-- (1976-1989)
10 SYNTHETIC FUELS
ACCIDENTS
AFRICA
AMMONIA
CARBONACEOUS MATERIALS
CATALYSTS
CHEMICAL REACTIONS
COAL
COAL GASIFICATION
COAL GASIFICATION PLANTS
COAL PREPARATION
COMPRESSION
COMPRESSORS
CONTROL
CONTROL SYSTEMS
DESULFURIZATION
DUSTS
ENERGY SOURCES
ENGINEERING
EXPLOSIONS
FAILURES
FLUIDS
FOSSIL FUELS
FUELS
GAS COMPRESSORS
GASES
GASIFICATION
HYDRIDES
HYDROGEN COMPOUNDS
HYDROGEN PRODUCTION
INDUSTRIAL PLANTS
KOPPERS-TOTZEK PROCESS
MATERIALS
NITROGEN COMPOUNDS
NITROGEN HYDRIDES
OXYGEN PLANTS
PRODUCTION
REFRACTORIES
SAFETY ENGINEERING
SHIFT PROCESSES
SHUTDOWNS
SOUTH AFRICA
START-UP
SYNTHESIS
SYNTHESIS GAS
TEMPERATURE CONTROL
THERMOCHEMICAL PROCESSES