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Development Of An Advanced Continuous Mild Gasification Process For The Production Of Coproducts Report For Task 48 Decontamination And Disassembly Of The Mild Gasification And Char To Carbon Prus And Disposal Of Products From Testing
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Book Synopsis Development of an Advanced, Continuous Mild-gasification Process for the Production of Coproducts. Report for Task 4.8, Decontamination and Disassembly of the Mild-gasification and Char-to-carbon PRUs and Disposal of Products from Testing by :
Download or read book Development of an Advanced, Continuous Mild-gasification Process for the Production of Coproducts. Report for Task 4.8, Decontamination and Disassembly of the Mild-gasification and Char-to-carbon PRUs and Disposal of Products from Testing written by and published by . This book was released on 1991 with total page 33 pages. Available in PDF, EPUB and Kindle. Book excerpt: This report contains descriptions of mild-gasification and char-to-carbon process research units (PRUS) used by WRI and AMAX R & D Center to conduct tests under contract AC21-87MC24268. Descriptions of materials produced during those tests are also contained herein. Western Research Institute proposes to dispose of remaining fines and dried coal by combustion and remaining coal liquids by incineration during mid-1992. The mild-gasification PRU will be used for additional tests until 1993, at which time WRI proposes to decontaminate and disassemble the PRU. AMAX R & D Center intends to return the spent char, any remaining feed char, and unusable product carbon to the Eagle Butte Mine near Gillette, Wyoming, from where the coal originally came. The solid products will be added to the mine's coal product stream. Coal liquids collected from condensers will be concentrated and sent to a local oil and solvent recycling company where the liquids will be burned as fuel. The char-to-carbon PRU will be operated periodically until 1993 when the plant will be decontaminated and disassembled.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Task 4.8, Decontamination and Disassembly of the Mild Gasification Process Research Unit and Disposal of Co-products by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Task 4.8, Decontamination and Disassembly of the Mild Gasification Process Research Unit and Disposal of Co-products written by and published by . This book was released on 1992 with total page 79 pages. Available in PDF, EPUB and Kindle. Book excerpt: Prior to disassembly of the CFBR, accumulated tar residue must be removed from the reactor, piping and tubing lines, and the condenser vessels. Based on experience from the CFBR mild gasification tests, lacquer thinner must be pumped through the unit for at least one hour to remove the residual tar. The lacquer thinner wash may be followed by a water wash. The CFBR will be disassembled after the system has been thoroughly flushed out. The following equipment must be disassembled and removed for storage: Superheater; Water supply pump; Coal feed system (hopper, auger, ball feeder, valves); Reactor; Cyclone and fines catch pot; Condensers (water lines, glycol bath, condenser pots, valves); and Gas meter. After the process piping and reactor have been disassembled, the equipment will be inspected for tar residues and flushed again with acetone or lacquer thinner, if necessary. All solvent used for cleaning the system will be collected for recycle or proper disposal. Handling and disposal of the solvent will be properly documented. The equipment will be removed and stored for future use. Equipment contaminated externally with tar (Level 4) will be washed piece by piece with lacquer thinner after disassembly of the PRU. Proper health and safety practices must be followed by the personnel involved in the cleanup operation. Care must be taken to avoid ingestion, inhalation, or prolonged skin contact of the coal tars and lacquer thinner. Equipment contaminated internally by accumulation of residual tar or oil (Level 5) will be flushed section by section with lacquer thinner. The equipment will be washed with solvent both before and after disassembly to ensure that all tar has been removed from the piping, pumps, gas quench condensers, light tar condensers, and drain lines. The coal tars wig be separated from the solvent and incinerated.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products (Tasks 2, 3, and 4.1 to 4.6), Volume 2. Final Report by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products (Tasks 2, 3, and 4.1 to 4.6), Volume 2. Final Report written by and published by . This book was released on 1991 with total page 205 pages. Available in PDF, EPUB and Kindle. Book excerpt: Volume 2 contains information on the following topics: (1) Mild Gasification Technology Development: Process Research Unit Tests Using Slipstream Sampling; (2) Bench-Scale Char Upgrading Study; (3) Mild Gasification Technology Development: System Integration Studies. (VC).
Book Synopsis Development of an Advanced Continuous Mild Gasification Process for the Production of Coproducts by :
Download or read book Development of an Advanced Continuous Mild Gasification Process for the Production of Coproducts written by and published by . This book was released on 1990 with total page 83 pages. Available in PDF, EPUB and Kindle. Book excerpt: Western Research Institute (WRI) teamed with the AMAX Research and Development Center and Riley Stoker Corporation on Development of an Advanced, Continuous Mild-Gasification Process for the Production of Coproducts under contract DE-AC21-87MC24268 with the Morgantown Energy Technology of the US Department of Energy. The strategy for this project is to produce electrode binder pitch and diesel fuel blending stock by mild gasification of Wyodak coal. The char is upgraded to produce anode-grade carbon, carbon black, and activated carbon. This report describes results of mild-gasification tests conducted by WRI. Char upgrading tests conducted by AMAX will be described in a separate report.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products (Tasks 2, 3, and 4. 1 to 4. 6) by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products (Tasks 2, 3, and 4. 1 to 4. 6) written by and published by . This book was released on 1991 with total page 205 pages. Available in PDF, EPUB and Kindle. Book excerpt: Volume 2 contains information on the following topics: (1) Mild Gasification Technology Development: Process Research Unit Tests Using Slipstream Sampling; (2) Bench-Scale Char Upgrading Study; (3) Mild Gasification Technology Development: System Integration Studies. (VC).
Book Synopsis Development of an Advanced Continuous Mild Gasification Process for the Production of Coproducts by :
Download or read book Development of an Advanced Continuous Mild Gasification Process for the Production of Coproducts written by and published by . This book was released on 1991 with total page 106 pages. Available in PDF, EPUB and Kindle. Book excerpt: Morgantown Energy Technology Center (METC) of DOE has sponsored, and continues to sponsor, programs for the development of technology and market strategies which will lead to the commercialization of processes for the production of coproducts from mild gasification of coal. It has been recognized by DOE and industry that mild gasification is a promising technology with potential to economically convert coal into marketable products, thereby increasing domestic coal utilization. In this process, coal is devolatilized under non- oxidizing conditions at mild temperature (900--1100°F) and pressure (1--15psig). Condensation of the vapor will yield a liquid product that can be upgraded to a petroleum substitute, and the remaining gas can provide the fuel for the process. The residual char can be burned in a power plant. Thus, in a long-term national scenario, implementation of this process will result in significant decrease of imported oil and increase in coal utilization.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products written by and published by . This book was released on 1988 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Research on mild gasification is discussed. The report is divided into three sections: literature survey of mild gasification processes; literature survey of char, condensibles, and gas upgrading and utilization methods; and industrial market assessment of products of mild gasification. Recommendations are included in each section. (CBS) 248 refs., 58 figs., 62 tabs.
Book Synopsis Development of an Advanced Continuous Mild Gasification Process for the Production of Coproducts. Task 4, System Integration Studies by :
Download or read book Development of an Advanced Continuous Mild Gasification Process for the Production of Coproducts. Task 4, System Integration Studies written by and published by . This book was released on 1991 with total page 110 pages. Available in PDF, EPUB and Kindle. Book excerpt: This document describes the results of Task 4 under which a 50 pound/hour char-to-carbon (CTC) process research unit (PRU) was designed in the second half of 1989, with construction completed in June 1990. The CTC PRU at Golden was operated for nearly one year during which 35 runs were completed for a total of nearly 800 hours of operation. Char methanation and carbon production reactor development activities are detailed in this report, as well as the results of integrated runs of the CTC process. Evaluation of the process and the carbon product produced is also included. It was concluded that carbon could be produced from mild gasification char utilizing the CTC process. Char methanation and membrane separation steps performed reasonably well and can scaled up with confidence. However, the novel directly heated reactor system for methane cracking did not work satisfactorily due to materials of construction and heat transfer problems, which adversely affected the quantity and quality of the carbon product. Alternative reactor designs are recommended.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products (Task 1) by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products (Task 1) written by and published by . This book was released on 1991 with total page 324 pages. Available in PDF, EPUB and Kindle. Book excerpt: Under US DOE sponsorship, a project team consisting of the Institute of Gas Technology, Peabody Holding Company, and Bechtel Group, Inc. has been developing an advanced, mild gasification process to process all types of coal and to produce solid and condensable liquid co-products that can open new markets for coal. The three and a half year program (September 1987 to June 1991) consisted of investigations in four main areas. These areas are: (1) Literature Survey of Mild Gasification Processes, Co-Product Upgrading and Utilization, and Market Assessment; (2) Mild Gasification Technology Development: Process Research Unit Tests Using Slipstream Sampling; (3) Bench-Scale Char Upgrading Study; (4) Mild Gasification Technology Development: System Integration Studies. In this report, the literature and market assessment of mild gasification processes are discussed.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products written by and published by . This book was released on 1992 with total page 9 pages. Available in PDF, EPUB and Kindle. Book excerpt: The char produced in the 100-lb/hr process development unit has been magnetically cleaned by AMAX and returned to the Energy and Environmental Research Center (EERC). The final calcining step of the process is currently being performed in the 4-lb/hr continuous fluidized-bed reactor (CFBR). The liquid products generated by the PDU have been collected and split into usable fractions and fractions to be discarded. Samples of the coal-derived liquids have been sent to Merichem Corporation of Houston and Koppers Industries of Pittsburgh for determination of their usefulness as chemical feedstock for the production of cresylic acids and anode-grade-binder pitch. The technical and economic assessment performed by Xbi and J.E Sinor Consultants has been completed. The briquette testing being conducted at the EERC has produced high quality briquettes using a number of binder agents. The next step in the test matrix will include the use of coal-derived liquids from the PDU as the binder. An additional coal has been added to the mild gasification test matrix. AMAX recently acquired two eastern low-sulfur bituminous coals and suggested that a limited test schedule be conducted to determine the suitability of these coals for the mild gasification process. The sulfur levels in the raw coals are below the target levels suggested by the steel industry for metallurgical coke use. To date, it has not been possible to reach these goals using the high-sulfur Illinois Basin coals tested.
Book Synopsis Development of an Advanced Continuous Mild Gasification Process for the Production of Co-products. Final Report, September 1987--September 1996 by :
Download or read book Development of an Advanced Continuous Mild Gasification Process for the Production of Co-products. Final Report, September 1987--September 1996 written by and published by . This book was released on 1996 with total page 79 pages. Available in PDF, EPUB and Kindle. Book excerpt: Char, the major co-product of mild coal gasification, represents about 70 percent of the total product yield. The only viable use for the char is in the production of formed coke. Early work to develop formed coke used char from a pilot plant sized mild gasification unit (MGU), which was based on commercial units of the COALITE plant in England. Formed coke was made at a bench-scale production level using MGU chars from different coals. An evolutionary formed coke development process over a two-year period resulted in formed coke production at bench-scale levels that met metallurgical industries' specifications. In an ASTM D5341 reactivity test by a certified lab, the coke tested CRI 30.4 and CSR 67.0 which is excellent. The standard is CRI 32 and CSR 55. In 1991, a continuous 1000 pounds per hour coal feed mild coal gasification pilot plant (CMGU) was completed. The gasification unit is a heated unique screw conveyor designed to continuously process plastic coal, vent volatiles generated by pyrolysis of coal, and convert the plastic coal to free flowing char. The screw reactor auxiliary components are basic solids materials handling equipment. The screw reactor will convert coal to char and volatile co-products at a rate greater than 1000 pounds per hour of coal feed. Formed coke from CMGU char is comparable to that from the MGU char. In pilot-plant test runs, up to 20 tons of foundry coke were produced. Three formed coke tests at commercial foundries were successful. In all of the cupola tests, the iron temperature and composition data indicated that the formed coke performed satisfactorily. No negative change in the way the cupola performed was noticed. The last 20-ton test was 100 percent CTC/DOE coke. With conventional coke in this cupola charging rates were 10 charges per hour. The formed coke charges were 11 to 12 charges per hour. This equates to a higher melt rate. A 10 percent increase in cupola production would be a major advantage. 13 figs., 13 tabs.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Quarterly Technical Progress Report, April--June 1992 by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Quarterly Technical Progress Report, April--June 1992 written by and published by . This book was released on 1992 with total page 9 pages. Available in PDF, EPUB and Kindle. Book excerpt: The char produced in the 100-lb/hr process development unit has been magnetically cleaned by AMAX and returned to the Energy and Environmental Research Center (EERC). The final calcining step of the process is currently being performed in the 4-lb/hr continuous fluidized-bed reactor (CFBR). The liquid products generated by the PDU have been collected and split into usable fractions and fractions to be discarded. Samples of the coal-derived liquids have been sent to Merichem Corporation of Houston and Koppers Industries of Pittsburgh for determination of their usefulness as chemical feedstock for the production of cresylic acids and anode-grade-binder pitch. The technical and economic assessment performed by Xbi and J.E Sinor Consultants has been completed. The briquette testing being conducted at the EERC has produced high quality briquettes using a number of binder agents. The next step in the test matrix will include the use of coal-derived liquids from the PDU as the binder. An additional coal has been added to the mild gasification test matrix. AMAX recently acquired two eastern low-sulfur bituminous coals and suggested that a limited test schedule be conducted to determine the suitability of these coals for the mild gasification process. The sulfur levels in the raw coals are below the target levels suggested by the steel industry for metallurgical coke use. To date, it has not been possible to reach these goals using the high-sulfur Illinois Basin coals tested.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Quarterly Report, April--June 1995 by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Quarterly Report, April--June 1995 written by and published by . This book was released on 1995 with total page 11 pages. Available in PDF, EPUB and Kindle. Book excerpt: The objective of this research and development effort was to develop an advanced, continuous ''mild gasification'' process. The relative quantities and properties of the products are appropriate for making the concept economically and environmentally viable. In ''mild gasification, '' coal is converted under relatively mild conditions of temperature and pressure in the absence of air into products which include a high heating value gas, high aromatic condensibles, char and coke all with physical and chemical properties suitable for the anticipated end uses. Two tons of CTC/DOE continuous coke of 6 in. x 5 in. x 4 in. size was produced in the Pilot Demonstration Unit. This coke was tested under actual foundry conditions in a 96 in. diameter commercial cupola. The test was run on the first shift on April 19, 1995. The coke sample was used as a direct replacement for 25 percent of the coke charge. A total of 51 scrap iron charges were run with the CTC/DOE continuous coke. Results of the test were excellent. The two main indicators improved., Tap temperature increased from an average of 2846°F to 2890°F. Carbon pickup improved from 3.49 percent C to 3.59 percent C when the CTC coke, hit the bed. These results are very meaningful because they cannot be measured in the lab. ChemChar Research, Inc. in Columbia, Missouri, is evaluating CTC chars as potential agents for removing pollutants from gas streams. Composite CTC char treated with the ChemChar activation process resulted in promising results. A 11.8 percent toluene adsorption and 13.4 percent monochlorobenzene adsorption were achieved with CTC char after activation.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Task 4.6, Economic Evaluation by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Task 4.6, Economic Evaluation written by and published by . This book was released on 1992 with total page 187 pages. Available in PDF, EPUB and Kindle. Book excerpt: The principal finding of this study was the high capital cost and poor financial performance predicted for the size and configuration of the plant design presented. The XBi financial assessment gave a disappointingly low base-case discounted cash flow rate of return (DCFRR) of only 8.1% based on a unit capital cost of $900 per ton year (tpy) for their 129,000 tpy design. This plant cost is in reasonable agreement with the preliminary estimates developed by J.E. Sinor Associates for a 117,000 tpy plant based on the FMC process with similar auxiliaries (Sinor, 1989), for which a unit capital costs of $938 tpy was predicted for a design that included char beneficiation and coal liquids upgrading--or about $779 tpy without the liquid upgrading facilities. The XBi assessment points out that a unit plant cost of $900 tpy is about three times the cost for a conventional coke oven, and therefore, outside the competitive range for commercialization. Modifications to improve process economics could involve increasing plant size, expanding the product slate that XBi has restricted to form coke and electricity, and simplifying the plant flow sheet by eliminating marginally effective cleaning steps and changing other key design parameters. Improving the financial performance of the proposed formed coke design to the level of a 20% DCFRR based on increased plant size alone would require a twenty-fold increase to a coal input of 20,000 tpd and a coke production of about 2.6 minion tpy--a scaling exponent of 0.70 to correct plant cost in relation to plant size.
Book Synopsis Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Quarterly Report, October 30, 1991--January 2, 1992 by :
Download or read book Development of an Advanced, Continuous Mild Gasification Process for the Production of Co-products. Quarterly Report, October 30, 1991--January 2, 1992 written by and published by . This book was released on 1991 with total page 12 pages. Available in PDF, EPUB and Kindle. Book excerpt: During this quarter the work on Task 3, char upgrading, was in two areas; upgrading Penelec char made from Penelec filter cake to blast furnace formed coke, and evaluating various bituminous pitch binders. The formed coke from Penelec filter cake was of good quality with a high crush strength of 3000 pounds. The reactivity was not equal to that of conventional coke but it is felt that it could be made to equal conventional coke with further study, specifically by adding binder coal to the raw material recipe. The work evaluating bituminous pitch binders confirmed earlier thinking that will be valuable to a commercial scale-up. Asphalt binders are compatible with coal tar binders and produce a coke of equal quality. Hence asphalt binders can be used to supply deficiencies of tar production in units employing coals with insufficient volatile matter to supply enough tar for the coking process. Asphalt binders have about a 50% savings from coal tar pitch. During the 4th Quarter of 1991, a total of 15 Continuous Mild Gasification Unit (CMGU) test runs were made. Efforts continued to determine the optimum forward/reverse ratio to maximize coal feed rate. The success of these efforts has been limited with a maximum coal feed rate of 400 lbs/hr obtainable with a caking coal. The handicap of not having screw shaft heaters cannot be overcome by adjustment of the forward/reverse ratio.
Book Synopsis Production of Mild Gasification Coproducts by :
Download or read book Production of Mild Gasification Coproducts written by and published by . This book was released on 1994 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:
Book Synopsis Bench-scale Development of Mild Gasification Char Desulfurization: Technical Report, September 1, 1993 Through November 30, 1993 by :
Download or read book Bench-scale Development of Mild Gasification Char Desulfurization: Technical Report, September 1, 1993 Through November 30, 1993 written by and published by . This book was released on 1994 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:
