Commercial Potential For The Kellogg Coal Gasification Process

SUMMARY (47.4kb)						1
I	The Kellogg Coal Gasification Process (1.47MB)
	A	Introduction				2
	B	Typical Process Flow Sheet				3
	C	Process Alternatives				7
		1	Gas Purification			7
		2	Methane Synthesis			9
	D	Process Economics				11
		1	Pipeline Gas			11
			(a)	Secondary Product Recovery		13
		2	Hydrogen			15
		3	Synthesis Gas			15
	E	Effect of Variables on Economics				17
		1	Gasification Rate			17
		2	Combustion Rate			17
		3	Sodium Carbonate Loss			20
		4	Quench Level of Product Gases			20
		5	Temperature			20
		6	Ash Content of Melt			20
		7	Carbon Content of Melt			22
		8	Gas Velocity			22
	F	Discussion				22
		1	Materials of Construction			22
		2	Reaction Rates			23
		3	Combustion Efficiency			24
		4	Sodium Carbonate Loss			24
		5	Product Gas Heat Recovery			25
II	Summary of Bench Scale Work					26
	A	Chemical Process Research (2.59MB)				26
		1	Gasification Rates			26
		2	Combustion Rates			26
		3	Combustion Efficiency			42
		4	Chemistry of Ash Removal			42
		5	Viscosity Studies			44
		6	Salt Carryover			44
		7	Mineralization Studies			44
		8	Disposition of Sulfur in the Process			49
		9	Ash Settling Process			49
	B	Mechanical Development (4.9MB)				50
		1	Corrosion Studies			50
		2	Coal Feeding Studies			61
		3	Quench Tests			64
		4	Cross-Flow Contamination			64
		5	Salt Transport			71
		6	Bed Expansion			77
			(a)	Melt Studies		77
			(b)	Simulation Studies		81
			(c)	Effect of bed Height		86
		7	Molten Sodium Carbonate bed Degasification			94
		8	Melt Viscosity			94
		9	Salt Carryover			99
III	Proposed Pilot Plant (64.3kb)					103
IV	APPENDIX A - CONCEPTUAL PROCESS FLOW SHEET (953kb)					104
	A	Process Description (Commercial Plant)				104
		1	Section 100 - Coal Storage and Preparation			104
		2	Sections 200 and 600 - Gasification and Ash Removal			105
		3	Section 300 - Shift Conversion			108
		4	Section 400 - Gas Purification			108
		5	Section 500 - Methane Synthesis			109
		6	Section 1100 - Offsite Facilities			111
	B	Economics of Pipeline Gas				120
	C	Design Bases				125
V	APPENDIX B - REMAINING PROBLEMS (935kb)					127
	A	Present Status				127
	B	Continued Bench-Scale Work				127
		1	Chemical Process Research			127
		2	Mechanical Development			128
		3	Process Design			129
	C	Pilot Plant Program				129
		1	General Objectives			129
		2	Process Description of Pilot Plant			129
			(a)	Section 100 - Coal Handling Facilities		129
			(b)	Section 150 - Carbonate Handling Facilities		130
			(c)	Section 200 - Gasification		130
			(d)	Section 300 - Ash Removal		132
		3	Design Rationale			133
			(a)	Section 100 - Coal Handling Facilities		133
			(b)	Section 150 - Carbonate Handling Facilities		134
			(c)	Section 200 - Gasification		134
			(d)	Section 300 - Ash Removal		134
		4	Specific Objectives and Pilot Plant Program			135
			(a)	Sections 100 and 150 - Coal and Carbonate Handling		135
				1	Objectives	135
				2	Program	135
			(b)	Section 200 - Gasification		136
				1	Objectives	136
				2	Program	138
			(c)	Section 300 - Ash Removal		140
				1	Objectives	140
				2	Program	140
		5	Cost and Schedule of Program			142
VI	REFERENCES (423kb)					144