EDS Coal Liquefaction Process Development: Phase V. Final Technical progress Report, Volume I

EDS Coal Liquefaction Process Development: Phase V. Final Technical progress Report, Volume I - 1984

Abstract				i
Introduction				1
1	Operation of Recycle Coal Liquefaction Units (RCLU)			2
	1.1	Introduction and Summary		2
	1.2	Sponsor Coal Evaluations		2
		1.2.1	Illinois No. 6 Bituminous Coal (Monterey No. 1 Mine)	2
		1.2.2	Illinois No. 6 Bituminous Coal (Burning Star No. 2. Mine)	14
		1.2.3	Pittsburgh No. 8 Bituminous Coal (Ireland Mine)	14
		1.2.4	Pittsburgh No. 8 Bituminous Coal (Arkwright Mine)	19
		1.2.5	Wyoming Subbituminous Coal (Wydoak Mine)	22
		1.2.6	Australian Black Subbituminous Coal (Wandoan Mine)	24
		1.2.7	Texas Lignite (Big Brown Mine)	26
		1.2.8	Texas Lignite (Martin Lake Mine)	28
	1.3	Bottoms Recycle		30
	1.4	ECLP Support Studies		33
		1.4.1	Monterey No. 1 Mine Coal	33
		1.4.2	Wyodak Mine Coal Operations	33
	1.5	Liquefaction Reactor Hydrodynamics Tests		34
	1.6	Liquefaction Reaction Solids Summary		36
	1.7	Conclusions		38
2	Operation of the One Ton-Per-Day Coal Liquefaction Pilot Plant (CLPP)			43
	2.1	Sponsor Coal Evaluations
		2.1.1	Monterey Coal Evaluation	46
		2.1.2	Burning Star Coal Evaluation	48
		2.1.3	Ireland Coal Evaluation	50
		2.1.4	Wyodak Coal Evaluation	54
		2.1.5	Wandoan Coal Evaluation	56
		2.1.6	Big Brown Lignite Evaluation	59
		2.1.7	Martin Lake Lignite Evaluation	59
	2.2	Evaluation of Bottoms Recycle		61
	2.3	VGO Recycle Conversion Evaluation		65
	2.4	Liquefaction Reactor Hydrodynamic Tests		68
	2.5	Liquefaction Heat Release Studies		68
	2.6	Liquefaction Reactor Solids Summary		70
	2.7	Conclusions		72
3	Solvent Hydrogenation Studies			73
	3.1	Experimental Facilities and Procedures		73
	3.2	Catalyst Activity Maintenance Studies		73
	3.3	ECLP Support Studies		77
		3.3.1	Catalyst Screening (Ni/Mo-10 vs Co/Mo-20)	78
		3.3.2	Heavy Solvent Process Variable Studies	78
		3.3.3	Low Pressure Studies	78
		3.3.4	Martin Lake Process Variable Study	83
		3.3.5	ECLP Catalyst Activity Studies	83
4	Bench Units, Modeling and Correlation Studies			88
	4.1	Tubing Bomb Autoclave Studies		88
		4.1.1	Correlations of Coal Conversion with Coal Properties	88
		4.1.2	Liquefaction Conversion of Wyoming Coal Bottoms from CLPP	91
		4.1.3	Tubing Bomb Investigation of Bottoms Recycle of Sponsor Coals	91
		4.1.4	Tubing Bomb Simulation of Heavy Liquid Recycle	92
		4.1.5	Solvent Cracking Study in Tubing Bombs	93
		4.1.6	Coal Screening and Process Variable Studies	93
		4.1.7	Tubing Bomb Evaluation of Solvent Quality Effects on Bottoms Recycle Coal Conversion	94
		4.1.8	Reactor Hydrodynamics Support Study	94
		4.1.9	Gas Swept Mill Coal Drying Study	95
		4.1.10	Slurry Drying Study	97
	4.2	Design and Operation of 15 Pound-Per-Day Once Through Coal Liquefaction Unites (OTCLU)		97
		4.2.1	Operability Study with Wyoming Coal	99
		4.2.2	High Pressure, Coal-Only Study	99
		4.2.3	Solvent Cracking Study on the Once-Through Coal Liquefaction Unit (OTCLU)	99
		4.2.4	Liquefaction of Neat Bottoms	100
		4.2.5	Vacuum Gas Oil (VGO) Conversion Study	100
	4.3	EDS Coal Liquefaction Model Development		101
		4.3.1	Empirical Coal Liquefaction Model	101
		4.3.2	Fundamental Coal Liquefaction Model	103
		4.3.3	Semi-Empirial Coal Liquefaction Model	104
		4.3.4	Solvent Hydrogenation Model	105
		4.3.5	Integrated EDS Coal Liquefaction Yield Model	105
		4.3.6	EDS Generic Coal Liquefaction Model	106
5	Product Quality Studies			107
	5.1	Summary of Research Results		107
	5.2	End-Use Applications of EDS Products		108
	5.3	Future Product Quality Needs		111
Laboratory Process Research and Development Bottoms Process Research
6	Coking and Gasification Studies			114
	6.1	EDS Flexicoking Studies		114
		6.1.1	Experimental Facilities and Procedures	114
		6.1.2	Major Conclusions and Results	116
	6.2	Refractory - Coal Ash Interactions Study		120
	6.3	Laboratory Studies of ECLP Preheater Coking		126
		6.3.1	Bench Slurry Coking Studies	126
		6.3.2	Slurry Preheater Coking Studies on a Flow Unit	126
	6.4	EDS Bottoms Characterization		136
		6.4.1	Introduction	136
		6.4.2	Major Considerations	136
ECLP Project Management, Detailed Engineering, Procurement, Construction and Operations
1	Project Management			142
2	Engineering and Procurement			142
3	Construction			142
4	Preparation and Operations			142
5	Operations			142
	5.1	ECLP Simplified Flow Plan		142
	5.2	Summary of ECLP Operations		144
		5.2.1	ECLP Start-up and Shakedown	144
		5.2.2	First Turnaround - October, 1980	144
		5.2.3	Illinois Coal Testing Operation	146
		5.2.4	Second ECLP Turnaround - June 1981	146
		5.2.5	First Wyoming Coal Operation	147
		5.2.6	Third ECLP Turnaround - November, 1981	148
		5.2.7	Illinois Coal Bottoms Recycle Operation	148
		5.2.8	Second Wyoming Coal Bottoms Recycle Operation	149
		5.2.9	Fourth ECLP Turnaround	150
		5.2.10	Texas Lignite Bottoms Recycle Operations	151
		5.2.11	Final ECLP Inspection	151
	5.3	ECLP Equipment Performance		152
		5.3.1	Drums	152
		5.3.2	Towers	153
		5.3.3	Slurry Pumps	154
		5.3.4	Reactors	155
		5.3.5	Valves	155
		5.3.6	Miscellaneous Equipment	156
	5.4	ECLP Safety and Occupational Health Programs		158
	5.5	ECLP Operating Data		158
	5.6	ECLP Product Shipments		161
6.0	ECLP Environmental Assessment			160
ECLP Termination of Operation
1.0	Dismantling			160
Appendices
Appendix A		ECLP Flow Plan		166
Appendix B		ECLP Operating History		168
Appendix C		ECLP Tabulated Yield Period Data		176
List of Abbreviations				184