List of Appendices

x

List of Figures

xi

List of Tables

xiv

Glossary

xv

1.0

Summary

1

2.0

Introduction

1

3.0

Project Background

1

4.0

Overview of Process

3

5.0

Overview of Design Considerations

9

5.1

Civil Design

9

5.2

Mechanical Design

17

5.3

Electrical and Instrumentation Design

28

6.0

Major Equipment Functions and Descriptions

34

6.1

Feed Coal System

34

6.2

Coal Dryer and Cyclone

34

6.3

Coal Pyrolyzer and Cyclone

41

6.4

Quench Table

42

6.5

PDF Cooler

42

6.6

PDF Product System

44

6.7

Quench Tower

44

6.8

Electrostatic Precipitators

47

6.9

Coal Derived Liquid (CDL) Handling System

47

6.10

Dryer Blower

52

6.11

Pyrolyzer Blower

52

6.12

Combustors

53

6.13

Purge Gas Treatment

53

6.14

Dust Scrubbers

58

7.0

Utilities

60

7.1

Steam System

60

7.2

Instrument and Plant Air

60

7.3

Cooling Water

60

7.4

Glycol/Water Circulating System

61

7.5

Potable Water

61

7.6

Firewater

63

7.7

Nitrogen

63

7.8

Natural Gas

64

8.0

Construction

64

8.1

Contracting Methodology

64

8.2

Contract Packages

66

8.3

Earthwork, Surveying, and Testing

66

8.4

Storage Silos

67

8.5

PDF Plant

69

8.5.1

Foundations

72

8.5.2

Underground Piping, Conduit, and Equipment Foundations

74

8.5.3

Mechanical Erection

8.6

Screening Building

85

8.7

Above Ground Piping

87

8.8

Architectural Buildings

87

8.9

Electrical and Instrumentation

89

8.10

Miscellaneous

92

9.0

Environmental Concerns

96

9.1

Air Pollutants

96

9.2

Water Effluents

96

9.3

Solid/Hazardous Waste Generation

97

10.0

Safety Practices

97

10.1

Industrial Hygiene

98

10.2

Physical Hazards

98

10.3

Construction Safety Practices

98

11.0

Conclusions

100