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ABSTRACT
This paper deals with the optimum design of
heat recovery systems using the Texaco Coal
Gasification Process (TffiP).
TffiP uses an
entra' ned type gasifier and produces hot gases at
approximately 2500 0 F with high heat flux.
This
heat is removed by using a combination of
radiant/convective waste heat boiler or by direct
water quench before processing of the raw gas.
The selection of an optimum heat recovery system
is a function of the product slate, overall
economics, and the technical risks associated with
the heat recovery equipment. An extensive use of
heat recovery equipment is not necessarily more
economical than a simpler system with modest
thermal efficiency.
INTRODLCTION
The use of coal derived synthesis gas for
alternative energy or raw material source for
chemicals has received considerable attention in
both electric utility and hydrocarbon processing
industries.
Unlike some existing producer gas
technologies
that
are
designed
for
small
industrial uses, the second and third generation
coal gasification processes are being developed to
use coal on a massive scale. These processes are
designed to operate under high pressure and
temperature conditions thereby resulting in better
conversion efficiency, higher throughput, and
minimal environmental effluents.
Hot
syngas,
at
approximately
2500 0 F,
(assumed for the purpose of this study) enters the
radiant waste heat boiler from the gasi fil~r
chamber. Here the syngas is cooled by generatilJn
of high pressure steam.
The syngas from the
radiant boiler is further cooled by the use of
convecti ve boilers and an economizer. More hiqh
pressure steam is generated in a convective boih!r
and the boiler feed water is preheated in an
economizer before entering convective and radiant
boilers for steam generation. The cooled syngas
then enters a carbon scrubber for further
processing. Table I shows a typical composition
of the synthesis gas after heat and water removal.
893
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
ESL-IE-82-04-159
as
COAL---_
OXYGEN----.
PAHTlCUlATE-FR~E
SYNGAS
RADIANT
CDNV.
WHB
WHB
SCRUBBER
SLAG
FIG 1.
TABLE I
Component
H2
CO
C02
CH4
~+Ar
H2S
COS
TOTAL
Vol. Percent
Raw Gas
Clean Gas
34.48
43.31
19.83
0.05
2.16
0.16
0.01
100.00
35.67
44.79
17.26
0.05
2.23
Negligible
60 ppmv
100.00
Radiant Boiler
The dense and hot syngas from the gasifier
A radiant
has a considerable high heat flux.
chamber, erclosed by water tube panels, is
designed to accommodate falling slag and to
provide sufficient hot gas residerce time for heat
dissipation. The radiant tube arrangement bears
resemblance to that of a cylindrical fired
heater.
The radiant heating surface of a
conventional coal-fired utility boiler is; usually
calculated to cool the gas temperature ~o below
17000 F to minimize the fouling of downstream
convection tube banks.
Because the fine slag
particles in the dense syngas environment are
expected to "float II longer than that of a
conventional boiler, a much lower radiant boiler
exit temperature is proposed to solidify the slag
particles.
894
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
ESL-IE-82-04-159
OJ
STACK
PUIIT
..
COAl
MRSG
SLURRY
PLAIT
I
I
ITEAli
TURIIIIE
I
I
I
J
COII0.....l
r------------
..l
'!!,A.!!.
'.'
GAl
TURIIIIE
ELECTRICITY
.--~.....,
ICRUI,
RAOIAIT
AID
ECOID,
WIll
CDOLlI.
"ZI
REMOVAL
IULfUR
LOCK
"Oml
ILAI
FIG. 2.
Convective Boiler
The convective boiler is essentially a
pressure vessel filled with steam generating water
tube banks. As the efficiency of radiant boiler
declines, the use of convection type heat transfer
provides
economical
advantage.
The
syngas
temperature at the exit of the convective boiler
is designed to optimize the heat transfer area
before the syngas enters the economizer for
further cooling. It is expected that the syngas
temperature at the exit of the convective boiler
will be below 700oF.
Economizer
The Economizer is used to further cool the
syngas from the convective boiler by preheating
boiler feed water.
The syngas is cooled to
slightly above its dew point.
Either fire-tube or water-tube economizers
can be used.
Fire-tube design offers better
fouling resistance, but the water-tube design is
easier to clean with soot blowers. Because of the
low heat absorption rate, the economizer is the
least economical when compared to radiant and
convective boilers.
However, for a ffiCC plant
with a long investment payback period, the use of
economizers appears to be economically viable.
895
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
'.
;.
.'_.
','
~.. "
ESL-IE-82-04-159
CMounET
1l1li%
noa
110a
I--L....-----IL....-----IL...-----IL.-........_
11
20
30
4CI
1.
........' - -........_--I'-----II.---IL..
10
7D
II
FIG 3.
TABLE II
HEAT RECOVERY EQUIPMENT COST*
Equipment Type
$/lb Steam
Per Hr.
Radiant Boiler
30-40
Convective Boiler
20-25
Economizer
80-120
(water-Tube)
60-90
(Fire-Tube)
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
ESL-IE-82-04-159
TABLE III
Case I
Case II
Load Distribution
64% Radiant
36% Convective
49% Radiant
51% Convective
2550 0 F
2550 0 F
1370OF
1490 0 F
Base
70%
$ 7.0 t+1
$5.53 MM
$ 3.2 t+1
$3.60 MM
Total
$10.2 t+1
$9.13 t+1
Saving
Base
$1.09 t+l
897
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
ESL-IE-82-04-159
Gz
PLANT
COAL
SLURRY
PLANT
AU)(
STEAM
SYSTEM
__ _
r--------..
I
......... ..-.-.-.IUl'lHtfUTtO
........ -.... .....
GASIFIER
SI'EAM
....
Off-GAS
SUPER
HUHR
DIRECT
QUENCH
SCRUII.
HZS
COt
REMOVAL
HEAT
RECOVERY
SHIFT
PSA
LOCK
HOPPER
IlAO
.,
OXYGEN
'ARIICULAH fREE
$VNGA$
GASIfIER WITH
QUENCH POOL
I
\
I I
I I
SCHUBBfR
I I
-=.=.:;:=-~-I-r-
I I
CHARGE
PUMP
SLAG
898
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
HI
ESL-IE-82-04-159
,,"
Case 1 -
Case 2 -
Partial
heat
recovery
radiant boiler only.
Case 3 -
with
Case 2
Case 3
Quench Unit
$27 t-t-1
$16 M'o1
$3 MM
+ $3 M'o1
+ $2 M'o1
Base
300,000 lbs/hr
135,000 lbs/hr
None
20,000 lbs/hr
21,000 lbs/hr
25,000 lbs.hr
142,000 lbs/hr
10,000 lbs/hr
None
158,000 lbs/hr
125,000 lbs/hr
None
Differential in
Electricity Requirement
+1.3 MW
+0.9 MW
Base
+$0.48 MM
+$0.33 MM
Base
$5.88 M'o1
$4 .65 M-.1
None
+27 MM
+15 M'o1
Base
+5.4
+4.32 M'o1
Base
Notes:
899
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
;'
ESL-IE-82-04-159
DxnEI
PLAIT
nAtl
nUM
f--------------------------------
I
r-----
I
I
I
I
f---------r----
r--------!~-----------J
,--""""'....0...,
MUHAIDL
lUI
FIG. 6
BLOCK FLOW
DIAGR~
900
Proceedings from the Fourth Industrial Energy Technology Conference, Houston, TX, April 4-7, 1982
ESL-IE-82-04-159
TABLE V
POWER/METHANOL CO-PRODUCTION PLANT COMPARISON*
Case 1
Case 2
Full heat
Recovery
Radiant Boiler
WQuench
$27 MM
$16 t+1
Diff. Offsites
$ 3 MM
$ 2 MM
Steam Generated
300,000 Ib/hr
135,000 Ib/hr
Steam Injection
125,000 Ib/hr
Steam Export
175,00 Ib/hr
135,000 Ib/hr
Soot Scrubber
$0.8 t+1
$0.5 MM
Quench Vessel
None
$0.4 MM
Total Investment
$30.8 MM
$18.9 MM
Diff Revenue
+1.49 MM
Base
.I.
II
,un
MoOH
f'
COAL
IlURRY
'UN'
HID
t
DIlI'RIIlID
1AIIIIlR
I
RADIAN'
WHI
IlETHUOl
".THUII
I-
WATER
DUINCH
foo-
KRUI
IHIf'
II
t
HII
AlIlOVAl
..,
I
LOCI
HD"U
IlAi
ESL-IE-82-04-159
COI'CLUSION
An optimized coal gasification waste heat
recovery system design has an important influence
on
the
overall
thermal
efficiency
and
cost-effectiveness of a synfuel plant. Al though
the design criteria and investment cost may vary
for different types of final products, some basic
gasification heat recovery systems can be
generalized.
o For ffiCC, the system design should
include maximum waste heat recovery
equipment in order to obtain an overall
thermal efficiency that is comparable to
that of a conventional coal-fired power
plant.
o For hydrogen generation purposes, a
gasification system employing a radiant
waste heat boiler and quench is thermally
efficient, but a direct quench system
with heat recovery after shift conversion
is more cost-effective.
o For
electric
power
and
methanol
co-production plants, a side stream for
partial quench offers good overall
thermal
efficiency
and
product
flexibility.
REFERENCES
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