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Scale-Up Requirements of the EXXON Catalytic Coal Gasification Process.
Final Report - 1979

S. J. Cohen

EXXON Research and Engineering Company

In this pdf format, this report has 87 pages and is 3.44MB.

Table of Contents

Abstract

ii

Section 1

 Background and Summary 1
 

1.1

 Introduction 1
1.2 Contract Objectives 1
1.3 CCG Process Concept 2
1.4 Facilities Description for a Commercial-Scale CCG Plant 2
1.5 Summary of Results 4
1.6 Qualifications of Results 5
 

Tables
1.1 Summary of Key Results 7
 

Figures
1.1 Exxon Catalytic Gasification Process 8
1.2 Flowplan for Catalyst Addition; Recovery and Recycle 9
1.3 Flowplan for Recycle Gas Loop 10
1.4 Reactor System Sketch 11
 

Section 2

Study Design and Cost Estimate for a Grass-Roots Large Pilot Plant

 12
  2.1 Project Basis 12
2.2 Process Basis 12
2.3 Design Philosophy 12
2.4 LLP Size - Key Scaleup Issues 13
2.5 Grass-Roots Case Flow Plan Basis 14
2.6 Investment Summary Grass-Roots Case 15
 

Tables
2.1 Illinois No. 6 Coal Analysis 17
2.2 Investment Summary for Grass-Roots Large Pilot Plant 18
2.3 Direct Cost Summary Grass-Roots Large Pilot Plant 19
2.4 Basis for Cost Escalation Estimate Grass-Roots Large Pilot Plant 20
2.5 Operating Cost Summary Grass-Roots Large Pilot Plant 21
2.6 Service Factor Basis 22
2.7 Operating Cost Estimating Basis for Grass-Roots Large Pilot Plant 23
 

Figures
2.1 Grass-Roots Case Insite Coordination Flow Plan 26
2.2 Engineering and Construction Schedule for Grass-Roots Large Pilot Plant 27
 

Section 3

Selection of The Preferred Existing Pilot Plant

 28
  3.1 Introduction 28
3.2 Factors Considered in Evaluation 28
3.3 Land Availability Comparison 29
3.4 Reusable Equipment Comparison 30
3.5 Conclusions 30
 

Tables
3.1 Comparison of Facilities Spacing for Proposed Modifications to Existing Pilot Plants 34
3.2 Existing Facilities Comparison: Coal Receipt, Storage and Preparation 35
3.3 Existing Facilities Comparison: Gasifier, Char Handling and Gas Processing 36
3.4 Existing Facilities Comparisons: Utilities and Disposal Systems 39
3.5 Facilities to be Dismantled 41
 

Figures
3.1 Plot Plan Revisions Synthane Pilot Plant 44
3.2 Plot Plan Revisions HYGAS Pilot Plant 45
3.3 Plot Plan Revisions Steam-Iron Pilot Plant 46
 

Section 4

Study Design and Cost Estimate for Major Synthane Revamp

 47
  4.1 Project Basis 47
4.2 Process Basis 47
4.3 Design Philosophy 47
4.4 LLP Size 47
4.5 Summary of Modifications to Synthane Plant 47
4.6 Investment Summary for Major Synthane Revamp 49
 

Tables
4.1 Catalytic Gasification LPP: Summary of Facilities Differences Grass Roots Versus Major Synthane Revamp 52
4.2 Investment Summary for Major Synthane Revamp 53
4.3 Basis for Cost Escalation Estimate - Major Synthane Revamp 54
4.4 Total Erected Cost Comparison: Major Synthane Revamp Versus Grass-Roots 55
4.5 Direct Cost Summary - Major Synthane Revamp 56
4.6 Direct Cost Breakdown: Grass-Roots Versus Major Synthane Revamp 57
4.7 Operating Cost Summary - Major Synthane Revamp 58
4.8 Operating Cost Estimating Basis - Major Synthane Revamp 59
 
Figures
4.1 Block Process Diagram Major Synthane Modification Case 62
4.2 Engineering and Construction Schedule-Major Synthane Revamp 63
 

Section 5

 Study Design and Cost Estimate for Minimum Synthane Revamp 64
  5.1 Project Basis 64
5.2 Process Basis 64
5.3 Design Philosophy 64
5.4 LPP Size 64
5.5 Summary of Modifications for Synthane Revamp 65
5.6 Investment Summary - Minimum Synthane Revamp 68
 

Tables
5.1 Comparison of Revamp Alternatives Conversion of Synthane to CCG Operation 69
5.2 Synthane Minimum Modification Revamp Project Cost Summary 70
5.3 Estimate Basis Synthane Minimum Modification Revamp 71
5.4 Synthane Minimum Modification Revamp Direct Cost Summary 74
5.5 Synthane Minimum Modification Revamp Operating Cost Summary 75
 

Figures
5.1 Synthane Revamp Minimum Modification Case 76
5.2 Synthane Minimum Modification Revamp 77
5.3 Project Schedule 77
 
Appendix 1: Details of Study Design for Grass Roots Case (4.8MB)
Appendix 2: Details of Study Design for Major Synthane Revamp Case (3.45MB)
Appendix 3: Details of Study Design for Minimum Synthane Revamp Case (2.64MB)