F E-2447-9

Distribution Categories UC-gOc, UC-90d

NOTICE
Tha repon 4 s prepared u an account of work
sponsored by the United States Govemmnt. Netther the
United S u l c i nor the United Stater Deputment of
h r w . nor any of their employees. nor any or their
ItrnIM REPORT m m c t o n . subcontracton, or their employees. maker
any vrrranty, express or implied. or assumes any IC@
lvbility 01 rerponnbility for the accuracy. eornplctcnerr
a upfulnm of any informtion. apparatur. product or
P r m n d & l w d . or reprennu that its upc would "08
idnngc pnntclyo-d nghu.

GxmI B ~ O R:S
H, FRITZSCHE (LURGIMINERALOELTECHNIK GMBH)
A. J. D I ~ + ~ I(P~BIL
O RESEARCH AND DEVELOF~IENT CORPJ
A, M, PESKIN (AMERICAN LURGI CORP,)

DAX ~LISHED - SEPTEFIEER

1977

UNDER CONTRACT No, EF-76-C-01-2W

i
 DISCLAIMER

This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States
Government nor any agency Thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal
liability or responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process
disclosed, or represents that its use would not infringe privately
owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or
otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any
agency thereof. The views and opinions of authors expressed herein
do not necessarily state or reflect those of the United States
Government or any agency thereof.
 DISCLAIMER

Portions of this document may be illegible in

electronic image products. Images are produced
from the best available original document.
I

!
 TABLE OF CONTENTS
Page

ABSTRACT 5
SUMNARY 6
1. STUDY SCOPE 10

2. STUDY DESIGN BASES 15

3. BASE CASE I : MOBIL METHANOL CONVERSION TECHNOLOGY

3.1 Material Balance 21

3.2 Product Yields and Quality 22
3.3 Thermal Efficiency 28
3.4 Process Descriptions 30
3.5 Offsite Units 75
3.6 Utility Requirements and Steam/BFW Balance 89
3.7 Train Philosophy 91
4. BASE CASE 11: FISCHER-TROPSCH TECHNOLOGY

4.1 Material Balance 94

4.2 Product Yields and Quality 95
4.3 Thermal Efficiency 103
4.4 Process Descriptions 105
4.5 Offsite Units 141
4.6 Utility Requirements and Steam/BFW Balance 147
4.7 Train Philosophy 149

REFERENCES 150

APPENDIXES
TABLES
2.1 Study Coal Properties 16
3.2.1 Comparison of Principal Unleaded Gasoline
Specifications with Estimated Methanol-to-
Gasoline Gasoline Properties (Case I) 25
3.2.2 Principal Unleaded Gasoline Specifications 26
3.2.3 Comparison of Principal LPG Specifications
with Estimated blethanol-to-Gasoline LPG
Properties (Case I) 27
3.3.1 Methanol-to-Gasoline Case I-Thermal Efficiency 29
3.4.1 Methanol Conversion Unit 150 - Process Design
Conditions for Fixed Bed 48
3.4.2 Methanol Conversion Unit 150 - Base Feed and
Product Composition 50
3.4.3 Methanol Conversion Unit 150 - Catalyst
,6mid Properties 52

-3 -
 TABLE OF CONTENTS
/ = =

Page
4.2.1 Comparison of Principal Unleaded Gasoline
Specifications with Estimated Fischer-
Tropsch Gasoline Properties (Case 11) 97
4.2.2 Comparison of Principal Diesel Fuel
Specifications with Estimated Fischer-
Tropsch Diesel Fuel Properties (Case 11) 99
4.2.3 Comparison of Principal Fuel Oil and Gas
Turbine Fuel Oil Specifications with
Estimation Fischer-Tropsch Heavy Fuel Oil
Properties (Case 11) 100
4.2.4 Comparison of Principal LPG Specifications
with Estimated Fischer-Tropsch LPG
Properties (Case 11) 102
4.3.1 Fischer-Tropsch Case 11-Thermal Efficiency 104
4.4.1 Fischer-Tropsch Conversion Unit 250 -
Product Composition 113 1
FIGURES
3.4 Block Flow Diagram - Base Case I (ZO-GEM-6894) 58
3.4 Process Flow Diagram - Base Case I 59-74
3.5 Schematic Flow Diagrams - Base Case I 87-88
3.6 Steam/BFW Balance - Base Case I (ZO-GEM-6910) 90
4.4
4.4
Block Flow Diagram - Base Case I1 (20-GEM-6988) 127
Process Flow Diagrams -
Base Case I1 128-140 /
4.6 Steam/BFW Balance - Base Case I1 (ZO-GEM-6986) 148

-4.-
 ABSTRACT

The primary purpose of this study is to provide a technical and

economic comparison between the commercial Fischer-Tropsch
technology and the new Mobil rnethanol-to-gasoline technology for
the production of motor gasoline. Several technical sensitivity
cases are also part of the study.
Two conceptual plant complexes - Base Case I: Mobil Technology
and Base Case 11: Fischer-Tropsch Technology - have been
developed. They are self-supporting, grass roots facilities
assumed t o be located in a Wyoming coal field. Plant size is
equivalent to the proposed large commercial SNG plants. Except
for the Mobil methanol conversion technology, all processes
used are commercial. Co-production of all products has been
assumed. Products have been upgraded to meet U.S. market specifica-
t ions.
A summary comparison between the two base cases is as follows:
Base Case I Base Case I 1
Technology Mobil Methanol Conversion Fischer-Tropsch
Net Coal Input, MST/SD a6.i 27.7
E d u c t Output, Bbl/SD(l) 50 , 075 48 , 760
SNG, % 48.5 59.4
Gasoline, % 44.0 27.9
Others , 70 7.5 12.7
Thermal Efficiency (HHV), 5% 62 58
Processing Steps ( 2 ) 9 18
SNG converted to barrels FOE @ 6.0 MMBtu/Bbl
(2) From clean syn gas to final co-products
somewhat more efficient and more effective
The Mobil t e c h n o l o g y is
in producing gasoline. IJoreover, the number of processing steps
required is considerably fewer.
All products meet the target specifications.
The technical discussions of the sensitivity cases and the economic
phase of the study will be added in the final report.

-5-
 SUMMARY

The following interim report only covers the technical development

of the two base cases. In the final report, the technical
development of the sensitivity cases, the economic phase and the
conclusions will be added.
The primary purpose of this scoping study is to provide a
technical and economic comparison between the commercial Fischer-
Tropsch technology and the new Mobil methanol-to-gasoline technology
for the production of motor gasoline. The primary coal gasification
step uses the commercial Lurgi dry-ash, moving-bed pressure
gasifier. Several technical sensitivity cases are also part of
the investigation. The base and sensitivity cases developed are
summarized below:
Base Cases ---------
, Sensitivity Zases---- -----
I I-c
Capacity Basis
I I1
Constant
I= -
I-AConstant Sy: gas
-
I -D II-A
3aseCaseI Constant
Syngas 3asoline Syngas
Technol o g y
Gasification* L L L L L W L
Conversion Mobil Fischer- MeOH hlobil Mobil Mobil hlobil
Fixed Tropsch only Fixed Fluid Fixed Direct
Bed Bed Bed Bed Route
Major Products
SNG X X X - X X
Gasoline eta1 X X - X X X
Methano1 - - X - - -

*L - Commercial Lurgi moving-bed pressure gasifier.

W - Winkler fluid-bed pressure gasifier under development.
The study bases adopted, essentially, follow those established in
"Coal Gasification Commercial Concepts Gas Cost Guidelines",
Reference 1. The conceptual plant complex developed for each
case is a self-supporting, grass roots facility, assumed to be
located adjoining a strip mine in Wyoming. Flant size is
equivalent to the large 280 MMSCF/SD commercial SNG plants under
consideration for Western coal. Except for the Mobil technology,
all processes used are commercially available.
Co-production of all products has been generally assumed. N o
marketing restrictions have been imposed. Products, however, have
been upgraded to meet U.S. market specifications, or in the case
of SNG, to be interchangeable with pure methane.

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 The overall material balances for Base Case I and I1 are shown
below:
Case I Case I1
Technology Mobil hlethanol Conversion Fischer-Tropsch
Input
Coal, as received, T/SD 27,334 27,698
Water, gpm 8,320 8,750
output
SNG , MMSCF/SD 148.5 173.3
C3 LPG, Bbl/SD 1,555 1,107
C4 LPG, Bbl/SD 2,205 146
10 RVP Gasoline, Bbl/SD 22,045 13,580
Diesel Oil, Bbl/SD -- 2,307
Heavy Fuel Oil, Bbl/SD Q -- 662
Alcohols, Mlb/SD -- 510
Sulfur, T/SD 61 61
Ammonia, T/SD 102 102
Coal Fines (excess), T/SD 1,230 0
Power (excess), M W 6.0 6.0
1 Thermal Efficiency (HHV), 70 62.2 57.8
The h-lobil technology is somewhat more efficient and more effective
in producing gasoline. The different yield patterns of the two
technologies are readily seen. A higher hydrocarbon liquid/SNG
thermal split (HHV) is obtained with the Mobil technology.
HC Liquid/SNG
Case I: 47/53
Case 11: 34/66

The steam/power balance is satisfactory for both cases as only

minor amounts of surplus power are obtained. In Case I , the
thermal balance does not require the usage of all the coal
fines produced during coal crushing. Greater energy requirements
result in an additional 1,594 T/SD of coal being fired in Case 11.
For both cases, about 6 barrels of water are required per barrel
of total FOE product.
The plant complexity necessary to convert the synthesis gas into
marketable products is much greater when using the Fischer-Tropsch
technology. The conceptual plant designs call for 18 units in
Case I1 compared to only 9 units in Case I.

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 n

The SNG properties are summarized below:

Case I Case 11
Technology Mobil Methanol Conversion Fischer-Tropsch
Cornposition, 7.,
1.7 3.8
95.5 89.7
I
c2= -- 1.0
0.2 2.3
c2
c3= -- 1.0
c3 0.1 0.1
c4 0.1 --
co2 0.5 0.5
Inerts 1.9 1.6
100.0 100.0
Heat of Combustion (HHV), Btu/SCF 980 @- 1,003
Compatibility Indexes (vs. Pure
Methane )
Lifting (11) 1.03* 0.99
Flash-Back (If) 1.02 1.06
Yellow-Tip (Iy) 1.05 0.97*
*Between preferable and objectionable values.
The SNG compositions differ reflecting the nature and amount of
the offgases from the methanol conversion and Fischer-Tropsch
sections. Both appear interchangeable with pure methane.
The estimated unleaded 10 RVP gasoline properties are in summary:
Case I Case I1
Technology Mobil Methanol Conversion Fischer-Tropsch Target
Gravity, OAPI 61.4 67.2 --
Octane, Unleaded
Research 93 91 --
Motor 83 83 82 min.
(R+M)/ 2 88 87 87 min.
Volatility
Reid Vapor Pressure, lb. 10 lo --
V/L Ratio (=20), OF 0 129.5 @ 127.3 @ 140 max.
Composition
Olefin, % 11 20 20 max.
Durene, % 4.6 -- 5 max.
Both gasolines meet all target specifications. Case I gasoline,
however, bests the octane targets by one number.

-8-
 he F-T fuel oils are of excellent quality, except perhaps their
ornewhat high cloud (pour) points. The diesel fuel could be
marketed under specifications for engines in service requiring
frequent speed and load changes. The clean, non-metal heavy fuel
oil would be a superior turbine fuel.

Further investigation of the cooling tower design parameters,

after the completion of this report, has reduced significantly
the fresh water requirements. In addition, offsite unit vendors
have provided more accurate utility requirements for their units.
These data will be incorporated in the final report.

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J
 SECTION 1
STUDY SCOPE

This study has been prepared as a joint effort by Mobil Research

and Development Corporation, Lurgi Mineraloeltechnik GmbII and
American Lurgi Corporation.
1.1 BASE CASES
The primary purpose of this scoping study is to provide
a technical and economic comparison between the commercial
Fischer-Tropsch technology and the Mobil methanol-to-
gasoline technology for the production of motor gasoline
from a U . S . coal. The primary coal gasification step
uses the Lurgi dry-ash, moving-bed pressure gasifier.
Base Case I is the co-production of gasoline and SNG using
the Mobil methanol-to-gasoline technology currently being
developed through joint funding by ERDA and i?fobil Research
and Development Corp. The methanol is first produced from
the coal derived synthesis gas.

Base Case I1 is the co-production of gasoline and SNG

,3 using the state-of-the-art Sasol-type Fischer-Tropsch
technology. The F-T products undergo e x t e n s i v e upgrading
to become marketable under U.S. specifications.
1.2 SENSITIVITY CASES
In addition to the above base cases, the following technical
sensitivity cases have also been evaluated:
Case I-A uses the same technology and synthesis gas
production as in Base Case I, except the Mobil methanol-to-
gasoline technology is eliminated and methanol and SNG
are the co-products.
Case I-B uses the same technology and synthesis gas
production as in Base Case I except the co-production of
SNG is eliminated. A reforming unit converts methane
into synthesis gas which is recycled to produce additional
methanol and, ultimately, additional gasoline.
Case I-C uses the same technology and synthesis gas
production as in Base Case I except the JAXobil methanol-to-
gasoline process uses a fluid-bed reactor in place of
the fixed-bed reactor used in Base Case I.

-10-
 Case I-D uses the non-commercial Winkler fluid-bed
pressure gasification technology in place of the
commercial Lurgi gasification technology. The Winkler
technology is under active development in Germany.
The methanol synthesis was adjusted for the different
synthesis gas composition. The gasification and methanol
synthesis steps yield the same quantity of methanol as
obtained in Base Case I. Because of the l o w methane
production in the Winkler gasifier, SNG manufacture has
been eliminated.
Case II-A uses the same technology and synthesis gas
production as in Base Case I 1 except the hlobil direct
route technology currently under development through
joint funding by ERDA and Mobil Research and Development
Corp. is substituted for the Sasol-type Fischer-Tropsch.
1.3 PLANT COhlPLEX DEFINITION
For each base case, a conceptual plant complex has been
developed. This complex is a self-supporting, grass roots
facility encompassing all process and offsite units.
Except for the Mobil and Winkler technologies, all
technologies used in the plant design are commercially
available. Location has been assumed to be adjacent a
strip coal mine in the State of Wyoming. Products
manufactured are available at the plant gate for shipment
to the market place.
1.4 DATA SOURCES
The process information contained in this scoping study
is based on either published or licensor data. (See
References.) Much of the coal gasification information
was derived from the proposed commercial Western SNG plants.
In fact, the conceptual plant complexes developed in this
study are nearly identical to these plants up through the
production of clean synthesis gas. The combining of the
processes used to obtain marketable SNG and gasoline from
the synthesis gas, for the most part, is based on the
in-house experience of the study participants. Licensors
were not contacted for information specific to this report.
No process or design optimfzation back-up studies have been
made. In addition, no specific laboratory work was done
for this study. As needed, in-house correlations, data banks,
engineering programs, cost estimating programs, etc., were used.

, Investment estimates are principally derived from in-house

data. Where obtainable, vendor quotes, however, have been
I used for the offsite units.

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I
1.5 SCOPE OF WORK
The work performed for each of the two base cases includes:
- material balance
- utility balance
- plant thermal efficiency
- block flow diagram
- simplified process flow diagrams
- equipment lists with major equipment dimensions
Each process unit is identified and briefly described with
pertinent design considerations indicated. For the hydro-
carbon upgrading processes, a technology critique is also
included. I n addition, the design bases used for the
methanol-to-gasoline and the Fischer-Tropsch units have
been outlined in some detail.
For each sensitivity case, the work performed has b.een
reduced to include only:
- overall simplified material balance
- approximateiutility balance
- p l a n t thermal efficiency
- simplified block flow diagram
Discussion is limited to the changes in the base case
brought about by the sensitivity. The discussion of the
Winkler pressure gasifier and its application in Sensitivity
Case I-D, as supplied by the Davy Powergas Inc., however,
is included in Appendix C.
Scoping or budget quality investment estimates have been
developed for the base cases. The investment for each
process and offsite unit is identified. Estimates of the
manpower catalyst requirements and chemical wages are also
provided. The investment estimates f o r the sensitivity cases,
for the most part, have been factored from the base cases.
New sensitivity unit investments, e.g., Winkler gasifier,
have been developed.
The plant complex economics have been calculated using
both utility financing and private investor financing.
Sensitivity of the unit cost towards coal price, SNG
price, byproduct values and investment and operating cost
shifts has also been developed f o r the base cases. An
abbreviated economic analysis is presented for the
sensitivity cases.

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.6 UNIT SUMMARY - BASE CASES
The plant complex is comprised of a series of inter-
connected process units, utility and support facilities
(offsite units) and general plant facilities (infra-
structure) as defined below:
PROCESS UNITS
Unit No. Description
Base Case I
101 Gasification (Lurgi Coal Pressure Gasification)
102 Raw Gas Shift
103 Raw Gas Cooling
104 Shifted Gas Cooling
105 Gas Purification (Rectisol)
106 Sulphur Recovery (Stretford)
107 Gas Liquor Separation
108 Phenol Recovery (Phenosolvan)
109 Ammonia Recovery (Chemie Linz/Lurgi)
110 Methanol Synthesis (Lurgi Low Pressure Process)
111 H2 Recovery (Pressure Swing)
112 Methanat ion
113 C02 Recovery (MEA Wash)
114 SNG Drying (TEG Wash)
150 Methanol Conversion (Blobil)
151 Naphtha Hydrotreating
152 Fractionation
153 HF Alkylation
Base Case I1
201 to 209 Identical to Base Case I
210 Hydrocarbon Recovery (Heptane Wash)
211 H2 Recovery (Pressure Swing)
212 Methanation
213 C02 Removal (MEA Wash)
214 SNG Drying (TEG Wash) and Cbmpression
250 F-T Synthesis
251 Naphtha Hydrotreating
252 F-T Product Fractionation
253 F-T Product Hydrotreating
254 Hydrotreated Product Fractionation
255 Catalytic Reforming
256 C5/Cg Isomerization
257 Catalytic Polymerization
258 HF Alkylation
259 Poly Gasoline Hydrogenation
260 Light Ends Recovery
261 H2 Purification
262 Alcohol Recovery

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 OFFSITE UNITS
( B a s e Case I a n d 1 1 )

Unit No. Description

121/221 Oxygen P r o d u c t i o n ( A i r S e p a r a t i o n )
1221222 Boiler
1231223 Main S u p e r h e a t e r
124/224 Superheater
125/225 E l e c t r o s t a t i c Stackgas P r e c i p i t a t o r
126/226 S t a c k g a s Clean-up
1271227 Instrument and P l a n t A i r
128/228 Coal Handling
1291229 Ash H a n d l i n g
131/231 BFW P r e p a r a t i o n ( D e a e r a t o r & D e m i n e r a l i z e r )
132/232 CW Make-up P r e p a r a t i o n
133/233 CW Towers
1341234 E l e c t r i c Power G e n e r a t i o n
1351235 Waste Water T r e a t m e n t ( B i o l o g i c a l )
136/236 R e l i e f a n d Blow Down F a c i l i t i e s
1371237 Storage
1381238 Interconnecting Piping
141/241 Refrigeration Unit
1541270 Gasoline Blending
271 F-T Catalyst Preparation

INFRASTRUCTURE
(Base Case I a n d 1 1 )
Office Buildings
Cafeteria
Maintenance Shops
Warehouse
Laboratory
F i r e P r o t e c t i o n System
Electric D i s t r i b u t i o n System
Truck and R a i l r o a d Unloading/Loading F a c i l i t i e s
Sewers
Roads a n d P a r k i n g L o t s
Fencing
General L i g h t i n g
Communication a n d S e c u r i t y

-14-
 SECTION 2
STUDY DESIGN BASES

ere applicable, the plant design bases adopted for this study
e generally those established by C.F. Braun & Co. fGr ERDA
in "Coal Gasification Commercial Concepts Gas Cost Guidelines"
(Reference 1). A discussion of the principal bases follows.
2.1 PLANT CAPACITY
For both base cases, the plant capacity is based upon the
gasification of 1,272 Mlb/hr of DAF coal. This amount of
coal produces 742 bIMSCF/SD of dry, purified synthesis gas
for feed to methanol synthesis (Base Case I) or feed to
Fischer-Tropsch synthesis (Base Case 11). For reference,
this capacity is equivalent to the capacity of the large
280 MMSCF/SD commercial SNG plants under consideration for
the United States and, thus, is similar to the Guidelines
plant size.
In the sensitivity cases, the gasification rate and synthesis
gas yield are the same as used in the base cases, except
for Sensitivity Case I-D. In this sensitivity, the 10 RVP
gasoline product is the same as the Base Case I.
Because of differing energy requirements, the total coal
charge, however, is not the same among the various cases.
2.2 DESIGN PHILOSOPHY
The overall plant complex has been designed using multiple
trains, spare equipment and intermediate storage to provide
an overall onstream factor of 92 percent. (.See Sub-sections
3.7 and 4.7.)
2.3 FEEDSTOCKS
The o n l y feedstocks to the plant complex, besides a i r , a r e
mined coal and fresh water. In addition, small quantities
of chemicals, solvents and catalysts are required.
2.3.1 Coal
Gasification and boiler-firing are based on a
coal having the properties listed in Table 2.1.
This coal is a low sulfur, Wyoming sub-bituminous
coal. Its properties differ slightly from the
base Montana sub-bituminous coal in the Guidelines.

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 TABLE 2.1
STUDY COAL PROPERTIES
(Wyoming Sub-Bituminous Coal)
Dry and Ash
As Received
- Free (DAF)

-
Proximate Analysis, wt. %
Moisture 28.0
Ash 5.1 --
Fixed Carbon 33.8 50.5
Volatile Matter 33.1 49.5
100.0 100.0

Ultimate Analysis, wt . %
74.45
5.10
19.25
0.75
0.45
100.00

Calorific Value, Btu/lb

High Heating Value (HHV) 8,509 12,720
Low Heating Value (LHV) 7,893 12,236
____________________-------------------------------.----- -- --- -- - - -_
-
- -- - ---Atmosphere-------
Fusion Properties of Ash, OF Oxidizing Reducing

Softening Point 2,335 2,335

Melting Point 2,360 2,360
Flow Point 2,440 2,430

Mineral Analysis of Ash Wt. %

Si02 19.0
14.0
6.0
7.8
36.0
2.7
0.2
7.0
Ba 0.2
TiOq 1.0
P205, 1.8
Undetermined 4.3
100.0

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 2.3.2 F r e s h Water

T h e q u a l i t y o f t h e u n t r e a t e d f r e s h water
a s s u m e d is t h e W e s t e r n l o c a t i o n water q u a l i t y
established i n t h e Guidelines. I n summary,
t h e t o t a l d i s s o l v e d s o l i d s are 496 ppm a n d
t h e t o t a l h a r d n e s s i s 232 ppm CaC03. It has
b e e n a s s u m e d t h a t t h e water i s a v a i l a b l e a t
t h e p l a n t gate.

2.4 CLIMATIC CONDITIONS

E s s e n t i a l l y , t h e climatic c o n d i t i o n s e s t a b l i s h e d i n
t h e G u i d e l i n e s h a v e been u s e d . I n summary, t h e y a r e :

Atmospheric p r e s s u r e , p s i a 12.3
A i r temperature (average), OF 50
R e l a t i v e humidity ( a v e r a g e ) , % 70
Summer w e t b u l b , O F 66

I1 2.5
Summer d r y b u l b , O F

PLANT SITE CONDITIONS

95

N o major s i t e d e v e l o p m e n t , o t h e r t h a n l e v e l i n g a n d g r u b b i n g ,
h a s been assumed. N o p i l i n g i s assumed t o be r e q u i r e d .

I 2.6 ENVIRONMENTAL REGULATIONS

The p l a n t c o m p l e x h a s b e e n d e s i g n e d t o meet a l l e x i s t i n g
local and f e d e r a l environmental r e g u l a t i o n s , as of
J u l y , 1977, f o r l i q u i d and g a s e o u s e f f l u e n t s .

B o i l e r stack g a s c l e a n - u p f a c i l i t i e s f o r SO2 r e m o v a l a r e
p r o v i d e d t o r e d u c e t h e SO2 e m i s s i o n s t o 0 . 2 p o u n d s of SO2
p e r m i l l i o n B t u of f i r e d h e a t . T h i s e m i s s i o n t a r g e t i s
more s e v e r e t h a n t h e b o i l e r SO2 l i m i t a t i o n i n t h e G u i d e l i n e s ,
b u t it i s representative of. t h e design limits placed on t h e
l a t e s t p r o p o s e d Western SNG p l a n t s . I n a d d i t i o n , an
electrostatic p r e c i p i t a t o r is included t o reduce t h e
p a r t i c u l a t e matter f r o m t h e b o i l e r t o 0 . 1 pound p e r m i l l i o n
B t u of f i r e d h e a t . (Note: F o r t h e p u r p o s e s of d e t e r m i n i n g
t h e "boiler" f i r e d d u t y , t h e main s u p e r h e a t e r is i n c l u d e d
a n d LHV i s t h e b a s i s . )

S u l f u r e m i s s i o n s f r o m t h e p r o c e s s u n i t s a r e r e d u c e d by
t r e a t i n g a l l s u l f u r containing offgases i n a s u l f u r recovery
unit. The t a i l gas stream c o n t a i n i n g 10 ppm H2S from t h i s
u n i t is i n c i n e r a t e d i n t h e b o i l e r t o e l i m i n a t e t h e h y d r o -
c a r b o n s a n d t o c o n v e r t t h e COS a n d H2S t o SO2 f o r r e m o v a l
i n t h e s t a c k gas c l e a n - u p f a c i l i t y . O n l y a b o u t 5% o f t h e
s u l f u r i n t h e t o t a l c o a l c h a r g e e s c a p e s as S02, amounting
t o a b o u t 5 T/SD o f s u l f u r .

-17-
 A l l aqueous l i q u i d e f f l u e n t s are t r e a t e d and r e c y c l e d .
Blowdown water i s u s e d f o r a s h s l u r r y i n g , d u s t c o n t r o l , e t c . .

The w e t a s h a n d s o l i d w a s t e s , e . g . , f r o m s t a c k gas
c l e a n - u p a n d water t r e a t i n g , a r e s e n t t o t h e mine f o r
disposal.

2.7 PRODUCTS

E x c e p t a s d i s c u s s e d b e l o w , t h i s s t u d y i s b a s e d on t h e
c o n c e p t t h a t a l l p r o d u c t s a r e marketable. O t h e r t h a n
q u a l i t y s p e c i f i c a t i o n s , no marketing r e s t r i c t i o n s have
been imposed. P r o d u c t s h a v e been c r e d i t e d w i t h t h e i r
h i g h e s t p o t e n t i a l market v a l u e . T h e major p r o d u c t s ,
h o w e v e r , a r e SNG a n d m o t o r g a s o l i n e . A p r o d u c t summary
is t a b u l a t e d b e l o w :
Base Case ----S e n s i t i v i t y Case----
Product
- I I1 I - A_ -
- - - _ I - B- I - C I-D 11-A

SNG X X X X X
Met h a n 0 1 - - X - - - -
Gasoline X X - X X X X
P r o p a n e LPG X X X X X X
B u t a n e LPG X X X X X
Diesel O i l - X - - -
Heavy F u e l O i l - X
Alcohols - X - - - - -
Ammonia X X X X X - X
Sulfur X X X X X X X
E l e c t r i c Power ( e x c e s s ) X X X X X x X
Coal F i n e s ( e x c e s s ) X

The L u r g i g a s i f i e r p r o d u c e s p h e n o l s , n a p h t h a , o i l a n d t a r
which are r e c o v e r e d d u r i n g r a w g a s c o o l i n g . For e x p e d i e n c y ,
t h e p h e n o l s , o i l and t a r are u s e d a s b o i l e r f u e l . Although
t e c h n i c a l l y p o s s i b l e , t h e u p g r a d i n g o f these materials i n t o
s a l e a b l e p r o d u c t s would h a v e l i t t l e , i f a n y , e f f e c t o n t h e
p l a n t complex e c o n o m i c s . On t h e o t h e r h a n d , t h e g a s i f i e r
naphtha is h y d r o t r e a t e d f o r g a s o l i n e blending, p r i n c i p a l l y ,
because t h i s a r o m a t i c s t o c k is needed t o y i e l d a s a t i s f a c t o r y
10 RVP g a s o l i n e i n t h e F i s c h e r - T r o p s c h case.

The F i s c h e r - T r o p s c h r e a c t i o n p r o d u c e s a s m a l l q u a n t i t y o f
a c i d s . They h a v e b e e n n e u t r a l i z e d w i t h c a u s t i c a s r e c o v e r y
is n o t e c o n o m i c a l ( 8 ) .
Ammonia a n d h y d r o g e n s u l f i d e o b t a i n e d d u r i n g r a w s y n g a s
p u r i f i c a t i o n a r e r e c o v e r e d a s a n h y d r o u s ammonia a n d s u l f u r .

-18-
2.8 PRODUCT SPECIFICATIONS

2.8.1 SNG

The SNG p r o d u c t is i n t e r c h a n g e a b l e w i t h p u r e
methane i n accordance w i t h p r o c e d u r e s d e s c r i b e d
i n t h e Guidelines. I n addition, it m e e t s
t h e following limitations:

Carbon monoxide 0.1 vol. %

Hydrogen s u l f i d e 0 . 2 5 g r a i n s / 1 0 0 SCF
Total s u l f u r 10 g r a i n s / 1 0 0 SCF
Water 4 lb/hlhlSCF,

and is a v a i l a b l e a t t h e p l a n t gate @ 1,000 p s i g .

2.8.2 Hydrocarbon P r o d u c t s

The t a r g e t s p e c i f i c a t i o n s a r e p r i m a r i l y b a s e d on
t h e 1976 Annual Book o f ASTM S t a n d a r d s a n d
represent industry guidance f o r e s t a b l i s h i n g product
p r o p e r t i e s between b u y e r a n d s e l l e r . P r o p e r t i e s
a n d comments s p e c i f i c t o t h e v a r i o u s h y d r o c a r b o n
p r o d u c t s can b e f o u n d i n t h e d i s c u s s i o n a n d t a b l e s
i n c l u d e d i n Sub-section 3 . 2 and 4 . 2 .

2.8.3 Alcohols

N o s p e c i f i c a t i o n s have been e s t a b l i s h e d . The

a l c o h o l p r o d u c t h a s been upgraded t o be e s s e n t i a l l y
f r e e of water, a c i d s , aldehydes and k e t o n e s .

2.8.4 Byproducts

- ---
Ammonia: A g r i c u l t u r e grade i s p r o d u c e d . ( W i t h a
r e l a t i v e l y s m a l l increase i n c o s t s , c h e m i c a l g r a d e
ammonia c o u l d b e p r o d u c e d b y t h e ammonia r e c o v e r y
p r o c e s s used i n t h e s t u d y . )

-
S u-l f-
ur: The p r o d u c t is a l i q u i d a t 95.5% p u r i t y .

-
E l-
e c-t r-
i c-Power:
-- Excess e l e c t r i c power i s p r o d u c e d
a t 6,000 v o l t s .

-19-
 2.9 COAL BALANCE

The minimum c o a l s i z e s p e c i f i c a t i o n f o r t h e L u r g i g a s i f i e r
u s e d i n t h e s t u d y is 1/4 i n c h . The m i n u s 1 / 4 i n c h c o a l
i s u s e d as b o i l e r f u e l . When c r u s h i n g t h e s t u d y c o a l , i t
h a s been e s t i m a t e d t h a t t h e c o a l p r e p a r a t i o n p l a n t y i e l d s
83.5% 2" t o 1/4" g a s i f i e r c o a l a n d 16.5% m i n u s 1/4" f i n e s .
S i n c e t h e s t u d y basis c a l l s f o r t h e combustion rather
t h a n r e c o v e r y of t h e g a s i f i e r t a r , o i l a n d p h e n o l s , a
s u r p l u s of f i n e c o a l i s p o s s i b l e . When t h i s o c c u r s , t h e
excess f i n e s a r e s o l d i n a c c o r d a n c e w i t h t h e G u i d e l i n e s .
2.10 UTILITY BALANCE

The g e n e r a l d e s i g n b a s e s c a l l s f o r i n - p l a n t power a n d
steam g e n e r a t i o n a n d , i f p o s s i b l e , no e x p o r t o f t h e s e i t e m s .
The u t i l i t y b a l a n c e s were d e v e l o p e d t o w a r d s t h i s g o a l , b u t
d e t a i l e d u t i l i t y r e b a l a n c i n g c a l c u l a t i o n s are o u t s i d e t h e
l i m i t s o f t h i s s c o p i n g s t u d y . T h u s , a s m a l l s u r p l u s of
e l e c t r i c power i s a v a i l a b l e f o r e x p o r t . I n t h e b a s e cases,
i t a m o u n t s t o l e s s t h a n 5% of t h e t o t a l steam a n d e l e c t r i c
power r e q u i r e d t o o p e r a t e t h e c o m p l e x .

-20-
 SECTION 3
BASE CASE I
MOBIL METHANOL-TO-GASOLINE TECHNOLOGY

3.1 MATERIAL BALANCE

The overall material balance is shown below:

Input Mlb/hr
Coal, as mined 2,227.8(1)
Air 5,733.8
Water 4,157.4
12,169.0

output bllb/hr
Coal fines 102.5(2)
Ash 140.1
Products 530.9( 3 ,
Byproducts 13.7
Blowdown water 508.8
Stack and vent losses 10,873.0
12,169.0
27,334 T/SD

(2) 1,230 T/SD

(3) 50,075 Bbl/SD
Overall plant consumptions per barrel of product, converting S N G
into a FOE barrel, are:
Coal: 0.521 T
Water: 5.69 B b l
Air: 1.37 T
Stack and vent losses amount to about 2.6 tons per barrel of
product. The C3 plus hydrocarbon yield ( 8 5 . 4 % 10 RVP gasoline)
is 0.509 Bbl/Bbl of converted methanol.
Appendix A contains the complete, detailed material balance for
Base Case I.

-21-
 BASE CASE I
3.2 PRODUCT YIELDS AND QUALITY

S t r e a m numbers a r e g i v e n b e l o w f o r r e f e r e n c e t o t h e material
balance sheets i n A p p e n d i x A a n d p r o c e s s d i a g r a m s i n S u b - s e c t i o n 3 - 4 ,

3.2.1 -
SNG ( 4 9 )

Quantity 16,306.3 lb-mol/hr

265.4 Mlb/hr
1 4 8 . 5 MMSCF/SD

C o m p o s i t i o n ( O n l y compounds g r e a t e r t h a n 0.1% a r e
l i s t e d : see A p p e n d i x A f o r d e t a i l e d
composition. )

Percent

Hydrogen 1.7
Methane 95.5
Ethane 0.2
Propane 0.1
Butane 0.1
Carbon dioxide 0.5
I n e r t s (N2 + Ar) 1.9
100.0
Other

Heat o f c o m b u s t i o n ( H H V ) 980 Btu/SCF

C a r b o n monoxide (0.1% max.) 0.02%
Water 0.01%
Sulfur None

C o m p a t i b i l i t y Indexes ( v e r s u s p u r e methane)
Index Calculated Preferable Object i o n a b l e

L i f t i n g , I1 1.03 under 1.0 above 1.06

Flash-back, I f 1.02 u n d e r 1.15 above 1 . 2
Y e l l o w - t i p , Iy 1.05 above 1 . 0 under 0.8

The SNG p r o d u c t is of s a t i s f a c t o r y q u a l i t y a n d i s c o m p a t i b l e w i t h
pure methane. The i n e r t s f r o m t h e oxygen stream f o r g a s i f i c a t i o n ,
however, g i v e r i s e t o a l i f t i n g i n d e x v a l u e between t h e p r e f e r a b l e
a n d o b j e c t i o n a b l e v a l u e s . From a p r o c e s s i n g s t a n d p o i n t , t h e r e is
l i t t l e t h a t c a n b e clone t o r e d u c e t h i s v a l u e . The s e l e c t i o n o f a
more e x p e n s i v e oxygen p l a n t y i e l d i n g a 99+% p u r e p r o d u c t , h o w e v e r ,
would a l l e v i a t e t h i s p r o b l e m . ( T h e SNG p r o d u c t , on t h e o t h e r h a n d ,
h a s a l i f t i n g i n d e x v a l u e b e t t e r t h a n t h e p r e f e r a b l e v a l u e when
compared w i t h t h e h i g h m e t h a n e n a t u r a l g a s s t a n d a r d c i t e d i n t h e
A.G.A. R e s e a r c h B u l l e t i n Number 36. T h i s gas h a s a 5.0% i n e r t s
content. )

-22-
3.2.2 Gasoline (50)

Quantity 22,045 Bbl/SD

235.7 Mlb/hr

Blending
Component Wt. %
Mixed butanes 2.4
Alkylate 3.2
Stabilized gasoline 87.8
Hydrotreated gasifier naphtha 6.6
100.0

Properties
Estimated properties and a comparison with unleaded
gasoline specifications are presented in Table 3.2.1.
Table 3 . 2 . 2 gives a more detailed listing of the
principai unleaded gasoline specifications.
The 10 RVP gasoline is of excellent quality and meets
all specifications. Its octane rating is estimated
to be about one above the specification number.
Volatility and composition are similar to present-day
gasolines. Although the content of the troublesome
durene is below the target maximum of 5.0 wt. %, it
would be preferable if it were below 4.0 wt. %. ( 2 )
3.2.3 Mixed Butanes (103)

Quant 2.ty 2,205 Bbl/SD

18.3 Mlb/hr

Properties
Estimated properties and a comparison with LPG
specifications are shown in Table 3.2.3.
This product is a satisfactory commercial butane
fuel. Because of the high iso-butane content of
76 vol. 70, it has, however, a higher potential
economic value as an alkylation unit feedstock.

-23-
3.2.4 Propane LPG (102j
Quantity 1,555 Bbl/SD n
11.5 Mlb/hr

Properties
Estimated properties and a comparison with LPG
specifications are shown in Table 3.2.3.
This product is a satisfactory commercial propane
fuel.
3.2.5 Byproducts
Sulfur (29)
Quant ity 61 T/SD
Impurities 0.5 wt. %
Anhydrous Ammonia (17)
Quantity 103 T/SD
Impurities (mainly water) 0.5 wt. % max.
Grade agricultural

Excess Power (6,000 volts) 5.96 hiW(e)

3.2.6 Coal Fines (2.1)

Quantity 102.5 Mlb/hr

The thermal requirements do not require the use of all

the fines produced in the coal preparation unit.

-24-
 TABLE 3.2.1
COMPARISON OF PRINCIPAL UNLEADED GASOLINE SPECIFICATIONS
WITH ESTIMATED METHANOL-TO-GASOLINE GASOLINE PROPERTIES-
CASE I

Estimated MTG
Unleaded Gasoline
Properties Specification
Gravity, OAPI 61.4
Octane Numbers
Research 93
Mot or 83 82 min.
(Research + Motor)/2 88 87 min.
Volatility

Reid Vapor Pressure, lb 10.0

Distillation, OF
IBP 85.5
10% 110.5 158 max.
30% 146.1
50% 200.0 170/250 min./max.
70% 262.8
90% 336.9 374 max.
EP 388.6 437 max.
V/L Ratio (=20), O F @ 129.5 @ 140 max.
Sulfur, wt. 5% Nil 0.10 max.
Composition, vol. %
Paraffins 51.3
Olefins 11.3 20 max. (target)
Naphthenes 8.7
Aromatics 28.7

Durene Content, wt. % 4.6 5 max. (target)

Mo 1ecu.1.ar We ight 94.3

-25-
 TABLE 3.2.2
PRINCIPAL UNLEADED GASOLINE SPECIFICATIONS
ASTM D439(l) OTHER POSSIBLE WAIVERS

Octane Numbers
(Research + Motor)/2,
min. (D2699 and D2700) 87
Motor, min. (D2700) 82

Volatility
Reid Vapor Pressure, max. (D323) 15(2) 15.5-16.0 (in winter)

Distillation, O F (D-86)
10% Evap. max. temp.
50% Evap. min./max. temp.
90% Evap. max. temp.
End Point, max. temp.
I % Recovered, min.
to
(r, $ Residue, max.
I
158(2) (140 avg.)
170/250(2) (avg. 240 rnax.)
374(2) (370 avg.)
437
- 95(3) No Spec.
- 2(3)

V/L Ratio, max. O F @ 20 (D2533) 140(2)

Existent Gum, max. mg/100 mls (D381) 5
Sulfur, max. wt. % (D1266) 0.10 0.15@)
Benzene, max. wt. %
Bromine Number, max. (D1159). -
Induction Period, min. (D525) -
Corrosion, max. (D130) No. 1
Lead Content, max. g/USG (D2547 or
D2599) 0.05

(1) 1976 Annual Book of ASTM Standards

(2) Lower max. limits apply according to season, geographical location, and individual state
specification.
(3) Applicable in several states.
(4) California
(5) Recommended
(6) ASTM ES-1-74 (Emergency) specifications f o r conventional (not 'unleaded) gasoline.
) Federal specification.
 TABLE 3.2.3
COMPARISON OF PRINCIPAL LPG SPECIFICATIONS WITH
ESTIMATED METHANOL-TO-GASOLINE LPG PROPERTIES-
CASE I

Commercial Est. MTG Commerci a1 Est. MTG

Propane C3 LPG Butane C4 LPG
ASTM D1835* Properties ASTM D1835* Properties
Vapor Pressure at 100°F, max. psig
(D1267) 208 171 70 52
Volatile Residue
41 Butane and Heavier, max. vol. % 2.5 1.9 - -
I
Pentane and Heavier, max. vol. % - - 2.0 0.7
Corrosion, max. (D1838) No. 1 No. 1 No. 1 No. 1
Sulfur, grains (D2784) 15 None 15 None

* 1976 Annual Book of ASTM Standards

I
 BASE CASE I
3.3 THERMAL EFFICIENCY

Table 3 . 3 . 1 i s a summary of t h e o v e r a l l p l a n t t h e r m a l e f f i c i e n c y ,
w h i c h i s d e f i n e d a s t h e c o m b u s t i o n h e a t of t h e p r o d u c t s , b y p r o d u c t s
a n d e x c e s s power d i v i d e d by t h e c o m b u s t i o n heat of t h e t o t a l
c o a l f e e d . The e f f i c i e n c y h a s b e e n c a l c u l a t e d u s i n g b o t h t h e
high and l o w h e a t i n g v a l u e s .

-28-
 c
TABLE 3.3.1
METHANOL-TO-GASOLINE CASE I - THERMAL EFFICIENCY

Quantity , High Heating , rota1 HHV, Percent of Low Heating, Percent of

Unit/SD Value (HHV) vlhlB tu/ h r Input Value (LHV) Net InDut
Input
Coal , DAF 18,286 T 12, 720Btu/lb 19 , 383
Fines excess ) (823 T) I1
(872)
Net CIa1 17,463 18,511

output
SNG 148.52MMSCF 980.4Btu/SCF 6,067 32.8 882.6Btu/SCF 30.7
I C3LPG 1,555 Bbl 3.816MMBtu/Bbl 247 1.3 3.509MMBtu/Bb 1.3
C LPG 2,205 Bbl 4.191MMBtu/Bbl 385 2.1 3.865MMBtu/Bb 2.0
I 18 RVP
Gasoline
Sub- Tota1
22,045 Bbl
- 4,689
11,388
25.3
61.5 1 4.771MMBtu/Bb 4,382
110,4 2 6
24.6
58.6
Sulfur
Ammonia
61 T
103 T
3,780 Btu/lb
9,693 Btu/lb
19 0.1
0.5
I 3.780 Btu/lb
8;020 Btujlb
I 19 0.1
0.4
Power(excese )5.96 MW(e) 3,415 Btu/kWH ::(2) 0.1 3',415Btu/kWH 0.1
Total 11,510 62.2 59.2

(1) If LHV of as mined coal used (7,893 Btu/lb), overall LHV thermal efficiency becomes 61.3%.
(.2) Direct thermal conversion used.

I
 BASE CASE I
3.4 PROCESS DESCRIPTIONS

The discussions below follow the block flow diagram (BFD) or the
process flow diagram (PFD) as noted. These diagrams are placed
at the end of the discussion. Detailed compositions and flows of
the numbered streams are found on the material balance sheets in
Appendix A .
3.4.1 General (BFD ZO-GEM-6894)
Sized coal is received from the offsite Coal Handling
Unit 128 (see Sub-section 3 . 5 ) and is gasified in Coal
Pressure Gasification Unit 101. The raw gas generated
is partially converted in Raw Gas Shift Unit 102 to
meet Methanol Synthesis Unit 110 requirements, and is
cooled in Raw Gas Cooling Unit 103 and Shifted Gas
Cooling Unit 104 before flowing to Gas Purification
Unit 105. This unit removes the H2S, C 0 2 and naphtha
from the raw gas. The purified gas (synthesis gas),
is compressed and fed into Methanol Synthesis Unit 110.
The crude methanol is used as feed to Methanol Conversion
Unit 150, which converts the methanol into gasoline.
S t a b i l i z e d gasoline is recovered in Fractionation Unit 152.
Additional gasoline is produced in HF Alkylation Unit 153
by alkylating the olefins recovered in Unit 152. C3 LPG
and mixed butanes are also recovered in the alkylation unit.
The naphtha recovered within Gas Purification Unit 105 is
upgraded in Naphtha Hydrotreating Unit 151.
The gasoline product is produced fron stabilized gasoline,
hydrotreated naphtha, alkylate and a portion of the mixed
butanes in the offsite Gasoline Blending Unit 154. (See
Sub-section 3 . 5 . )
The purge gas of Methanol Synthesis Unit 110, containing
mainly the methane of the synthesis gas, is sent to the
SNG upgrading train. This train consists of Methanation
Unit 112, where unreacted CO and H2 and higher hydrocarbons
are converted to additional methane, C02 Removal Unit 113
for upgrading the methane to SNG quality, and SNG Drying
Unit 114.
The hydrogen necessary f o r hydrotreating is produced in
H2 Recovery Unit 111 by absorption from a side stream of
the purge gas from Methanol Synthesis Unit 110. The offgas
of Unit 111 is recompressed to the SNG upgrading train
pressure.

-30-
 The H2S contained in the Gasification Unit 105 offgas
is converted in Sulphur Recovery Unit 106 to sulphur.
The gas liquors condensed in Units 101, 103, 104 and
105 are pumped to Gas Liquor Separation Unit 107, where
dusty tar and oil are recovered. The gas liquor is
processed further in Phenol Recovery Unit 108 and
Ammonia Recovery Unit 109.
Sulphur and anhydrous ammonia are saleable products.
Dusty tar, oil and phenols are not further upgraded,
but are used as fuel.
3.4.2 Gasification Unit 101 (PFD ZO-GEM-6895 and 6896)
Purpose of the Unit is to convert coal into raw synthesis
gas.
Technology Used
A s defined in the scope of the study, the Lurgi Coal
Pressure Gasification Process is used. This is a partial
oxidation process by addition of oxygen and steam in
the Lurgi countercurrent moving bed pressure gasifier.
Coal Handling Inside the Gasification Building
The well-sized coal is transported from Coal Handling
Unit 128 to the top of the gasifiers by two-100 percent
capacity inclined belt conveyors. During normal operation,
each belt conveyor operates at 50 percent capacity and
feeds two horizontal conveyors which run between two rows
of gasifiers. Two spare horizontal conveyors are provided.
Coal is fed from the horizontal conveyors to the coal
bunkers, 101-Y-01, by means of mobile automatic stations,
each of which consists of a t r i p p e r and a reversible b e l t .
Four stations have been provided with two stations normally
operating.
All coal handling in the gasification building is controlled
from a central control room.
Process Description
- - - - - - (PFD ZO-GEX-6895)
Gasification
The well-sized coal is charged from the coal bunkers, 101-Y-01,
into the gasifiers via automatically operated coal locks,
101-D-02. The bed of coal is gasified in countercurrent
flow with the gasification agent. While travelling from the
top to the bottom of the gasifier, the coal is dried,
devolatilized and gasified.

-31-
The g a s i f i c a t i o n a g e n t is a m i x t u r e o f oxygen a n d steam
which i s i n t r o d u c e d i n t o t h e b o t t o m of t h e g a s i f i e r
through a r o t a t i n g g r a t e . The a s h i s removed by t h i s
g r a t e a n d d i s c h a r g e d v i a t h e s e m i - a u t o m a t i c Ash Lock
101-D-03 a n d f l o w s t o Ash H a n d l i n g U n i t 1 2 9 .
The steam a d d i t i o n m o d e r a t e s t h e g a s i f i e r t e m p e r a t u r e
t o below t h e a s h l i q u e f a c t i o n p o i n t . The p a r t i a l corn-
b u s t i o n o f t h e c o a l w i t h t h e oxygen s u p p l i e s t h e h e a t
necessary f o r t h e g a s i f i c a t i o n reactions.

The h o t r a w gas l e a v i n g t h e g a s i f i e r i s c o o l e d a n d
s c r u b b e d i n Wash C o o l e r 1 0 1 - E - 0 1 w i t h r e c y c l e d g a s
l i q u o r . By t h i s o p e r a t i o n t h e c r u d e g a s i s s a t u r a t e d
w i t h steam a n d t h e d u s t a n d t h e h e a v y t a r s a r e removed.
Before leaving t h e u n i t , f u r t h e r cooling t a k e s place i n
Waste Heat B o i l e r 1 0 1 - E - 0 1 w h e r e 100 p s i g steam i s
produced.

The d u s t y g a s l i q u o r l e a v i n g t h e wash c o o l e r a n d t h e
waste h e a t b o i l e r is s e n t t o G a s L i q u o r S e p a r a t i o n U n i t 1 0 7 .
(PFD ZO-GEM-6896)
When t h e c o a l l o c k s a r e d e p r e s s u r e d , r a w gas i s r e l e a s e d .
The p o r t i o n w h i c h i s r e l e a s e d down t o a b o u t 70 p s i g i s
f e d t o t h e l a s t s t a g e of Lock G a s R e c o m p r e s s o r 101-C-41
a f t e r p a s s i n g t h r o u g h V e n t u r i S c r u b b e r 101-D-41. The
p o r t i o n w h i c h i s released down t o a t m o s p h e r i c p r e s s u r e i s
f e d t o t h e f i r s t s t a g e of t h i s r e c o m p r e s s o r v i a Lock G a s
H o l d e r 101-F-41.

The small q u a n t i t y e s c a p i n g d u r i n g t h e c h a r g i n g o p e r a t i o n
of t h e c o a l l o c k s , 101-D-02, i s n o t r e c o m p r e s s e d d u e t o
t h e p r e s e n c e o f a i r a n d i s e x h a u s t e d b y C o a l Lock S u c t i o n
Fan 1 0 1 - C - 0 1 t h r o u g h V e n t u r i S c r u b b e r 101-F-05 t o t h e
atmosphere.

The l o c k g a s r e c o m p r e s s o r a l s o c o m p r e s s e s t h e Gas P u r i f i c a -
t i o n U n i t 105 r e c o m p r e s s i o n g a s a n d t h e main c o m p r e s s o r
s y n g a s l o s s e s o f M e t h a n o l S y n t h e s i s U n i t 110 (Base Case I
only).

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3.4.3 R a w G a s S h i f t U n i t 1 0 2 (PFD ZO-GEM-6897)

P u r p o s e o f t h e U n i t i s t o i n c r e a s e t h e H2/CO r a t i o o f
t h e r a w s y n t h e s i s g a s t o meet t h e r e q u i r e m e n t s f o r
m e t h a n o l c o n v e r s i o n . Only a sidestream of t h e r a w g a s
h a s t o be c o n v e r t e d .

The e x o t h e r m i c s h i f t r e a c t i o n i s a s f o l l o w s :
d
CO + H20 / C02 + H2.

N o a d d i t i o n a l steam i s r e q u i r e d f o r t h e r e a c t i o n , s i n c e
s u f f i c i e n t steam i s c o n t a i n e d i n t h e r a w g a s .

I n a d d i t i o n t o t h e c o n v e r s i o n of CO, m o s t of t h e u n s a t u r a t e d
h y d r o c a r b o n s , h i g h e r p h e n o l s , HCN a n d o r g a n i c s u l f u r
are h y d r o g e n a t e d and t h e t a r i s h y d r o c r a c k e d i n t o o i l and
naphtha.

T e c h n o l o g y Used

For CO c o n v e r s i o n i n t h e r a w g a s g e n e r a t e d i n t h e L u r g i
g a s i f i e r , L u r g i h a s d e v e l o p e d a t e c h n o l o g y u s i n g commercial
catalysts.

Process D e s c r i D t i o n

The w a t e r c o n t e n t o f t h e r a w g a s f r o m G a s i f i c a t i o n U n i t 101
i s a d j u s t e d by c o o l i n g i n t h e 50 p s i g Waste S t e a m G e n e r a t o r
102-E-04. I n S e p a r a t o r 102-F-01, t h e c o n d e n s e d g a s
l i q u o r i s s e p a r a t e d f r o m t h e r a w g a s . The c o n d e n s e d g a s
l i q u o r t h e n f l o w s t o G a s L i q u o r S e p a r a t i o n U n i t 107 v i a
Raw G a s C o o l i n g U n i t 103.

I n Heat E x c h a n g e r s 102-E-01, 02 a n d 0 3 , t h e r a w g a s i s
h e a t e d t o r e a c t i o n t e m p e r a t u r e by h e a t exchange a g a i n s t
t h e s h i f t e d g a s . The r a w g a s t h e n f l o w s t o P r e r e a c t o r
102-D-01, w h i c h s e r v e s p r i m a r i l y a s a g u a r d bed t r a p p i n g
p o l y m e r i z e d h y d r o c a r b o n s a n d d u s t . The p r e r e a c t o r c a n b e
b y p a s s e d a n d r e g e n e r a t e d when t h e p r e s s u r e d r o p across
t h e c a t a l y s t b e d becomes e x c e s s i v e .

The p a r t i a l l y s h i f t e d g a s f r o m t h e p r e r e a c t o r f l o w s t o
Reactors 102-D-02 a n d 03 f o r f u r t h e r c o n v e r s i o n . The
s h i f t e d gas f r o m 102-D-03 is c o o l e d i n E x c h a n g e r s 102-E-01
a n d 0 2 a g a i n s t t h e r a w f e e d gas a n d t h e n f l o w s t o S h i f t e d
G a s Cooling Unit 104.

P r o v i s i o n s h a v e b e e n made t o p e r i o d i c a l l y r e g e n e r a t e t h e
c a t a l y s t u s i n g steam a n d a i r .

-33-
3.4.4 Raw Gas Cooling Unit 103 (PFD ZO-GEM-6898)

Purpose of the Unit is to cool the raw synthesis gas

coming from the gasifiers to a temperature as low as
possible using cooling water, thereby reducing the
downstream refrigeration requirements for gas purifica-
tion.
Within the dictated temperature limitations, heat is
recovered by the production of LP steam.
During cooling the raw gas, gas liquor, containing tar,
oil, phenols and ammonia, is condensed.
Technology Used
The technology used has been developed by Lurgi for the
special requirements of the Lurgi Coal Gasification Process.
Process Description
The raw gas is first cooled in the 50 psig Steam Generator
103-E-01. It is then cooled in the 20 psig Steam
Generator 103-E-102. To further reduce the raw gas
temperature, it is cooled by air in 103-E-03 and by cooling
water in 103-E-04. To prevent the formation of ammonium
carbonate, which could plug the tubes, gas liquor is
injected into 103-E-04.
The gas liquor condensed in these steam generators and
Trim Cooler 102-E-04 flows to Tarry G a s Liquor Tank
103-F-04. Part of the gas liquor is recycled to Wash
Cooler 101-E-01 in Unit 101; the balance is sent to
Gas Liquor Separation Unit 107.

3.4.5 Shifted Gas Cooling Unit 104 (PFD ZO-GEM-6899)

Purpose of the Unit is to cool the hot shifted gas to a
temperature as low as possible using cooling water,
thereby reducing the refrigeration requirements for gas
purification. (See Paragraph 3.4.4).
Technology Used
The technology used has been developed by Lurgi f o r the
special requirements of the Lurgi Coal Gasification Process.

-34-
 Process Description
The shifted gas is first cooled in the 100 psig Steam
Generator 104-E-01. The shifted gas is then cooled in
the 20 psig Steam Generator 104-E-02. TO further reduce
the shifted gas temperature, it is cooled by air in
104-E-03 and by cooling water in 104-E-04. To prevent
the formation of ammonium carbonates, which could plug
the tubes, gas liquor is injected into 104-E-04.
After 104-E-04, the shifted gas is compressed by Booster
Compressor 104-C-01 in order to overcome the pressure
drop of Raw Gas Shift Unit 102. The compressed shifted
gas is then cooled by 104-E-05 and combined with the
cooled raw gas from Unit 103.
The gas liquor from the coolers and steam generators
flows to Gas Liquor Separation Unit 107.
3.4.6 Gas Purification Unit 105 (PFD ZO-GEM-6900)
Purpose of the Unit is to remove the sulfur compounds and
carbon dioxide from the raw gas to the desired levels
required by the methanol conversion unit. Naphtha,
hydrogen cyanide and water are also removed.
Technology Used
The selected L u r g i Rectisol Process purifies the raw
gas by physical absorption using cold methanol as the
absorption agent. The Rectisol process is currently in
successful commercial operation. The application of this
process is most economic at a high partial pressure of
C02 in the feed gas.
Although a high selectivity of sulphur removal can be
achieved to meet the requirements of the Claus sulphur
recovery process, the non-selective route has been
chosen using the Stretford sulphur recovery process. The
Rectisol/Stretford combination is believed to be the
most economic system for a low sulphur coal, based on
previous studies for commercial-sized SNG plants.
The Naphtha and Methanol Recovery Section (NklR) of the
Rectisol process has been developed to meet special
requirements of the Lurgi Coal Gasification Process.

-35-
--

Process D e s c r i p t i o n
The R e f r i g e r a t i o n U n i t 1 4 1 m a i n t a i n s t h e two t e m p e r a t u r e n
l e v e l s o f -450F a n d 320F r e q u i r e d f o r g a s p u r i f i c a t i o n .
A b-s o-r b-
- e r -S-
e c-
tio
-n
The feed gas i s c o o l e d s e q u e n t i a l l y i n 105-E-01 w i t h
s y n t h e s i s g a s , i n 105-E-02 w i t h + 320F r e f r i g e r a n t , i n
105-E-03 w i t h s y n t h e s i s g a s and f l a s h gases and i n
i05-E-04 w i t h -45OF r e f r i g e r a n t . The f e e d g a s , a f t e r
c o o l i n g , e n t e r s t h e prewash s e c t i o n of Absorber
105-D-01 w h e r e i t i s washed w i t h a s m a l l q u a n t i t y o f
m e t h a n o l t o remove t h e n a p h t h a , HCN, a n d w a t e r . The
m a i n s e c t i o n o f t h e a b s o r b e r c o n s i s t s o f a low a n d a
middle s e c t i o n , w i t h an i n t e r m e d i a t e c h i l l i n g l o o p , where
t h e g a s is s c r u b b e d w i t h f l a s h r e g e n e r a t e d m e t h a n o l t o
remove t h e b u l k o f s u l p h u r compounds a n d c a r b o n d i o x i d e .
From t h e m a i n s e c t i o n t h e gas f l o w s t o t h e f i n e wash
section i n the top of t h e absorber. I n t h e f i n e wash
s e c t i o n , t h e g a s is s c r u b b e d w i t h h o t r e g e n e r a t e d m e t h a n o l
t o remove t h e r e m a i n i n g s u l p h u r compounds a n d c a r b o n
d i o x i d e t o t h e s p e c i f i e d l e v e l f o r methanol s y n t h e s i s .
The g a s t h e n e x i t s t h e u n i t b y heat e x c h a n g e w i t h t h e f e e d
g a s , a n d t h e syngas flows t o Methanol S y n t h e s i s U n i t 110.

The r i c h m e t h a n o l l e a v i n g t h e o o t t o m of A b s o r b e r 105-D-01
i s now r e g e n e r a t e d i n F l a s h R e g e n e r a t o r 105-D-02. The
l a d e n m e t h a n o l i s f l a s h e d i n s e v e r a l s t e p s down t o a s l i g h t
vacuum, where d i s s o l v e d g a s e s a r e r e l e a s e d . Gas f r o m t h e
f i r s t f l a s h s t a g e i s s e n t t o Lock G a s C o m p r e s s o r 1 0 1 - C - 4 1
t o r e c o v e r t h e b u l k of t h e c o - a b s o r b e d C H 4 , C O , a n d H 2 .
The o t h e r f l a s h gases a r e s e n t t o S u l p h u r R e c o v e r y U n i t 106

A p o r t i o n of t h e b o t t o m s o f t h e f l a s h r e g e n e r a t o r becomes
t h e semi-lean s o l u t i o n used i n t h e middle s e c t i o n of t h e
a b s o r b e r , w h i l e t h e remainder is f u r t h e r r e g e n e r a t e d i n
H o t R e g e n e r a t o r 105-D-03 b y a steam h e a t e d r e b o i l e r .
The f u l l y r e g e n e r a t e d methanol ( l e a n methanol) is u s e d
i n t h e t o p s e c t i o n of Absorber 105-D-01. The o f f g a s
l e a v i n g t h e h o t r e g e n e r a t o r i s combined w i t h t h e a b o v e
d e s c r i b e d f l a s h g a s e s and s e n t t o S u l p h u r Recovery U n i t 106.

-36-
 .N a. p h. t h. a . a n. d. M. e t. h a. n o. l . R.e c.o v. e r.y . S .e c.t i .o n
The m e t h a n o l f r o m t h e p r e w a s h s e c t i o n o f A b s o r b e r 105-D-01
i s f l a s h e d i n P r e w a s h F l a s h Column 101-D-04 b e f o r e i t
i s s e n t t o t h e n a p h t h a a n d m e t h a n o l r e c o v e r y s e c t i o n , which
i s shown as a b l o c k o n t h e PFD.
T h i s b l o c k c o n s i s t s o f : (1) M i x e r - S e t t l e r E x t r a c t o r
f o r r e c o v e r i n g o f n a p h t h a , ( 2 ) A z e o t r o p e Tower f o r f i n e
r e c o v e r y o f n a p h t h a , a n d ( 3 ) M e t h a n o l Water Tower f o r
r e c o v e r i n g of t h e prewash methanol.

The e x t r a c t i o n a g e n t i s b o i l e r f e e d w a t e r , w h i c h i s
r e c o v e r e d f r o m t h e b o t t o m o f t h e m e t h a n o l water t o w e r a n d
s e n t t o Waste Water T r e a t m e n t U n i t 1 3 5 .

The r e c o v e r e d n a p h t h a , w h i c h c o n t a i n s a l l of t h e o r g a n i c
s u l p h u r compounds a n d a b o u t 50% o f t h e HCN c o n t a i n e d i n
t h e raw g a s i s s e n t t o N a p h t h a H y d r o t r e a t i n g U n i t 1 5 1 .

The r e m a i n i n g 50% of t h e HCN w i l l l e a v e t h e NMR s e c t i o n a s

a HCN o f f g a s w h i c h i s r e c y c l e d by t h e Lock Gas C o m p r e s s o r
101-C-41 t o R a w G a s S h i f t U n i t 1 0 2 f o r c o n v e r s i o n t o
ammonia.

3.4.7 S u l p h u r R e c o v e r y U n i t 106 (PFD ZO-GEM-6901)

P u r p o s e of t h e U n i t i s t o r e c o v e r t h e s u l p h u r f r o m t h e
v a r i o u s a c i d g a s e s o f t h e p l a n t c o m p l e x . The s u l p h u r i s
r e c o v e r e d as e l e m e n t a l s u l p h u r w i t h a p u r i t y of 99.5%.

T e c h n o l o g y Used

The S t r e t f o r d P r o c e s s w h i c h w a s d e v e l o p e d b y t h e B r i t i s h
G a s Corp. i s used t o g e n e r a t e s a l a b l e , s o l i d s u l p h u r from
l o w c o n c e n t r a t i o n H 2 S gases. ( T h e s e gases a r e n o t s u i t e d
for t h e Claus p r o c e s s ) .
The S t r e t f o r d P r o c e s s i s a n a b s o r p t i o n p r o c e s s u s i n g a
sodium c a r b o n a t e s o l u t i o n w i t h a d d i t i v e s .

The o v e r a l l c h e m i c a l r e a c t i o n i n c l u d i n g a b s o r p t i o n a n d
r e g e n e r a t i o n is w r i t t e n a s :

2 H2S + 0 2 \
- 2 H20 + 2 S

-37-
 Process DescriDtion

The f e e d g a s i s c o n t a c t e d c o u n t e r c u r r e n t l y i n A b s o r p t i o n
Column 1 0 6 - D - 0 1 by t h e c i r c u l a t i n g S t r e t f o r d s o l u t i o n .
The H 2 S - f r e e g a s e x i t s t h e t o p of t h e a b s o r b e r a n d g o e s
t o U n i t 1 2 2 t o b e i n c i n e r a t e d . I t c o n t a i n s l e s s t h a n 1 0 ppm
of H 2 S . None o f t h e COS i n t h e f e e d gas, h o w e v e r , i s
absorbed.

The r i c h S t r e t f o r d s o l u t i o n e n t e r s R e a c t i o n Chamber 106-D-02

w h i c h p r o v i d e s t h e t i m e n e c e s s a r y f o r t h e c o m p l e t i o n of t h e
c h e m i c a l r e a c t i o n . Then, t h e r i c h S t r e t f o r d s o l u t i o n f l o w s
by g r a v i t y t o O x i d i z e r 106-D-03, w h e r e i t i s c o n t a c t r d w i t h
a i r . I n 106-D-03, t h e S t r e t f o r d s o l u t i o n i s o x i d i z c d f o r
r e u s e , and t h e s u l p h u r p a r t i c l e s f l o a t t o t h e t o p of t h e
l i q u i d as a f r o t h .

The r e g e n e r a t e d S t r e t f o r d s o l u t i o n o v e r f l o w s f r o m t h e
o x i d i z e r i n t o S o l u t i o n Pump Tank 106-F-01, a n d , a f t e r
c o o l i n g , i t is r e c y c l e d back t o t h e a b s o r b e r .

The s u l p h u r f r o t h f r o m t h e o x i d i z e r f l o w s b y g r a v i t y t o
Pump Tank 106-F-02, f r o m w h i c h i t i s pumped t o S u l p h u r
Vacuum Filter 106-F-03. From there it flows b y g r a v i t y
t o S u l p h u r Melter 106-E-02 a n d on t o M e l t e d S u l p h u r
A c c u m u l a t o r 106-F-04.

3.4.8 G a s L i q u o r S e p a r a t i o n U n i t 107 (PFD ZO-GEM-6902)

P u r p o s e of t h e U n i t i s t o s e p a r a t e by g r a v i t y t h e d u s t y
t a r , o i l and co-absorbed g a s e s from t h e v a r i o u s g a s
l i q u o r streams.

T e c h n o l o g y Used

The t e c h n o l o g y u s e d h a s b e e n d e v e l o p e d by L u r g i f o r t h e
s p e c i a l r e q u i r e m e n t s of t h e L u r g i Coal G a s i f i c a t i o n P r o c e s s .

Process Description

D
_ u-s-t y- -G-a s- -L i q u o r
The d u s t y gas liquor coming f r o m t h e waste h e a t b o i l e r i n
U n i t 101 a n d from 103-F-04 i n U n i t 1 0 3 i s c o o l e d i n 107-E-01
a n d mixed w i t h t h e c o o l e d g a s l i q u o r f r o m U n i t s 103 a n d 1 0 4 .
The m i x t u r e t h e n f l o w s i n t o T a r S e p a r a t o r 107-F-01 v i a
E x p a n s i o n Vessel 107-F-02. I n t h e t a r s e p a r a t o r , t a r is
s e t t l e d o u t i n t h e c o n i c a l b o t t o m s e c t i o n a n d pumped t o
Tank 107-F-10.

-38-
 The gas l i q u o r l e a v i n g 107-F-01 f l o w s by g r a v i t y t o
O i l S e p a r a t o r 107-F-04. The o i l s e p a r a t e d i n 107-F-04
f l o w s b y g r a v i t y t o O i l Tank 107-F-08. The g a s l i q u o r
flows by g r a v i t y t o S u r g e Tank 107-F-07.

_O i_l y_ G- a-s _L -i q_u o r

The o i l y gas l i q u o r coming f r o m Heat E x c h a n g e r s 104-E-01
a n d 0 2 of S h i f t e d Gas C o o l i n g U n i t 1 0 4 i s c o o l e d a n d t h e n
mixed w i t h t h e gas l i q u o r coming from Gas P u r i f i c a t i o n
U n i t 105. T h i s combined stream f l o w s by g r a v i t y , v i a
E x p a n s i o n Vessel 107-F-03, i n t o S e p a r a t o r 107-F-05, w h e r e
t h e s e p a r a t e d o i l f l o w s b y g r a v i t y t o O i l Tank 107-F-08.

G a-
- L i-
s - q u-
or

The gas l i q u o r l e a v i n g S e p a r a t o r 10'7-F-05 f l o w s by g r a v i t y

t o F i n a l S e p a r a t o r 107-F-06, w h e r e i t i s combined w i t h
t h e gas l i q u o r f r o m S u r g e Tank 107-F-07.

The gas l i q u o r s e p a r a t e d i n 107-F-06 f l o w s by g r a v i t y t o

F i n a l S u r g e Tank 107-F-09, a n d f r o m t h e r e , i t i s pumped
t o P h e n o l R e c o v e r y U n i t 108 f o r f u r t h e r t r e a t i n g . The o i l
r e c o v e r e d i n 107-F-06 f l o w s by g r a v i t y t o O i l Tank 107-F-08.

T
- a_r - a-n-d - O i l
The t a r is b u r n e d i n B o i l e r U n i t 1 2 2 . The o i l i s f u e l f o r
S u p e r h e a t e r s 1 2 3 a n d 1 2 4 . The v a r i o u s e x p a n s i o n g a s e s
a r e s c r u b b e d i n Ammonia S c r u b b e r 107-E-01 for ammonia
r e c o v e r y and t h e n s e n t t o S u l p h u r Recovery Unit 106.
3.4.9 P h e n o l R e c o v e r y U n i t 108 (PFD ZO-GEM-6903)

P u r p o s e o f t h e U n i t i s t o recover p h e n o l i c components f r o m
t h e gas l i q u o r .
T e c h n o l o g y Used

For t h e r e m o v a l of p h e n o l s , t h e L u r g i P h e n o s o l v a n P r o c e s s
is p r o v i d e d . I t is a solvent e x t r a c t i o n process using
d i - i s o p r o p y l e t h e r as t h e s o l v e n t . The P h e n o s o l v a n P r o c e s s
h a s b e e n commercially u s e d i n s y n g a s a n d t o w n g a s p l a n t s
b a s e d on L u r g i P r e s s u r e Coal G a s i f i c a t i o n a n d i s u n d e r
c o n s i d e r a t i o n f o r t h e p r o p o s e d U.S. SNG p l a n t s .

-39-
Process Description

The gas l i q u o r coming from G a s L i q u o r S e p a r a t i o n U n i t 107

f l o w s t o S a n d F i l t e r s 108-F-02, w h e r e a n y r e m a i n i n g
s o l i d s a r e removed. The f i l t e r s a r e backwashed w i t h
c l e a n e d g a s l i q u o r a n d t h e mud l i q u o r f r o m t h e f i l t e r s i s
r e t u r n e d t o U n i t 107. From t h e s a n d f i l t e r s , t h e c l e a n e d
gas l i q u o r f l o w s t o S a t u r a t i o n Column 108-D-01, w h e r e
i t i s s a t u r a t e d w i t h C02 i n o r d e r t o increase t h e
e f f i c i e n c y of e x t r a c t i o n .

The s a t u r a t e d g a s l i q u o r f l o w s by g r a v i t y t o t h e m u l t i - s t a g e ,
m i x e r s e t t l e r t y p e e x t r a c t o r , 108-D-02, t o b e d i v i d e d
i n t o a p h e n o l i c - s o l v e n t p h a s e an'd a d e p h e n o l i z e d - g a s - l i q u o r
phase.

The d e p h e n o l i z e d g a s l i q u o r f l o w s t o R a f f i n a t e S e t t l e r
108-F-06 f o r t h e p u r p o s e o f r e c o v e r i n g t h e r e m a i n i n g
s o l v e n t . From t h e r e t h e gas l i q u o r i s pumped t o Ammonia
R e c o v e r y U n i t 109.

The p h e n o l i c - s o l v e n t p h a s e f r o m t h e e x t r a c t o r f l o w s , v i a
E x t r a c t S e t t l e r 108-F-07, t o E x t r a c t R e c e i v e r 108-F-08.
I t t h e n i s pumped, v i a P a r t i a l - F e e d E v a p o r a t o r 108-E-02,
i n t o S o l v e n t R e g e n e r a t o r 108-D-04. I n t h e overhead of
t h i s c o l u m n , t h e b u l k of t h e s o l v e n t i s r e c o v e r e d a n d
pumped b a c k t o E x t r a c t o r 108-D-02. The b o t t o m p r o d u c t i s
a p h e n o l - s o l v e n t m i x t u r e w h i c h i s pumped i n t o P h e n o l
Tower 108-D-05, w h e r e t h e r e m a i n i n g s o l v e n t i s s t r i p p e d
o u t u s i n g l i v e steam.

The o v e r h e a d s o l v e n t - w a t e r m i x t u r e o f 108-D-05 i s r e t u r n e d
t o E x t r a c t S e t t l e r 108-F-07. The b o t t o m p r o d u c t of
p h e n o l s i s pumped t o Main B o i l e r U n i t 122 t o be b u r n e d .

A small p o r t i o n of t h e p h e n o l s i s r e c y c l e d , p a r t l y f o r
r e c o v e r i n g s o l v e n t f r o m t h e o f f g a s e s i n Vent S c r u b b e r
108-D-06 a n d p a r t l y f o r r e c o v e r i n g s o l v e n t f r o m U n i t 109
o f f g a s e s i n P h e n o l S o l v e n t S c r u b b e r 108-D-03. In the
upper p a r t of t h e phenol s o l v e n t s c r u b b e r , t h e s e o f f g a s e s
a r e s c r u b b e d by waste w a t e r f o r p h e n o l r e c o v e r y , b e f o r e
b e i n g s e n t t o S u l p h u r R e c o v e r y U n i t 106.

-40-
3.4.10 Ammonia Recovery Unit 109 (PFD ZO-GEM-6904)
Purpose of the Unit is to recover the ammonia from
the gas liquor before final treatment for use as
cooling water make-up.
Technology Used
The technology used has been jointly developed by
Chemie Linz and Lurgi, mainly for the purpose of
removing ammonia from the Lurgi gasifier gas liquor.
The product is a salable ammonia of either agriculture
or chemical grade.
Ammonia recovery in the Chemie Linz/Lurgi Process is
accomplished by the use of stripping and scrubbing
techniques without the addition of chemicals or solvents.
Process Description
After heating, the gas liquor enters Deacidifier 109-D-01,
where the remaining gases and phenosolvan solvent are
stripped out by reboiler steam. The gases leaving the
stripper are scrubbed with cooled waste water under
elevated pressure to remove ammonia. The stripped gases
are sent back to Phenol Recovery Unit 108. The gas
liquor containing the ammonia leaves the bottom of the
deacidifier and is pumped after cooling to Total Stripper
109-D-02, where all the ammonia and the remaining gases
are stripped out by reboiler steam under atmospheric
pressure.
The bottom product of the total stripper is the clean
gas liquor containing less than 100 ppm free ammonia.
It is sent after cooling to Waste Water Treatment Vnit 135
for final treating.
The overhead vapors from the total stripper are partially
condensed in the bottom of Acid Gas Scrubber 109-D-03
in order to increase the ammonia concentration. The
condensate is refluxed back to the total stripper.
In Acid Gas Scrubber 109-D-03, the vapors are scrubbed
by a recycled aqueous ammonia solution from the process.
The heats of reaction and condensation are removed by
cooled pump-arounds.

-41-
 The b o t t o m stream of t h e a c i d gas s c r u b b e r , w h i c h
c o n t a i n s f r e e ammonia a n d ammonium s a l t s , i s pumped
by 109-G-05 t o Ammonia S t r i p p e r 109-D-04. The
b o t t o m s of t h e ammonia s t r i p p e r , c o n t a i n i n g a h i g h l y
n
c o n c e n t r a t e d s t o i c h i o m e t r i c ammonium s a l t s o l u t i o n ,
is r e c y c l e d b a c k t o 109-D-01. T h e s t r i p p e d ammonia
from t h e ammonia s t r i p p e r o v e r h e a d f l o w s t o t h e a c i d
gas s c r u b b e r f o r r e c o v e r y .

The ammonia v a p o r f l o w i n g o v e r h e a d f r o m A c i d G a s
S c r u b b e r 109-D-03 i s c o n d e n s e d a n d d r i e d b y
c o m p r e s s i n g a n d c o o l i n g i n t h e Ammonia L i q u e f y i n g a n d
Drying (ALD) S e c t i o n b e f o r e b e i n g s e n t t o s t o r a g e .

A s m a l l l i q u i d stream c o n t a i n i n g water a n d o r g a n i c
s u b s t a n c e s i s removed i n t h e ALD S e c t i o n a n d s e n t
t o t h e main w a s t e water stream.

3.4.11 M e t h a n o l S y n t h e s i s U n i t 110 (PFD ZO-GEM-6905)

Purpose of t h e Unit is t o produce methanol from t h e

p u r i f i e d s y n t h e s i s gas.

Technology U s e d

F o r t h e p r o d u c t i o n o f m e t h a n o l , t h e L u r g i Low P r e s s u r e
Methanol S y n t h e s i s P r o c e s s h a s been s e l e c t e d . This
p r o c e s s o f f e r s maximum s a f e o p e r a t i o n d u e t o i t s
h i g h l y d e v e l o p e d r e a c t o r d e s i g n a n d h a s w i d e commercial
usage.

The (H2 + CO) c o n v e r s i o n i s 8 5 . 2 m o l . $I.

Process Description

The s y n t h e s i s g a s i s c o m p r e s s e d , S y n g a s C o m p r e s s o r
110-C-01, t o a b o u t 1100 p s i g a n d mixed w i t h t h e r e c y c l e
gas stream. T h e R e c y c l e G a s C o m p r e s s o r 110-C-02
c o m p r e s s e s t h e m i x t u r e t o o v e r c o m e t h e p r e s s u r e losses
of t h e r e c y c l e l o o p . T h i s l o o p c o n s i s t s o f Heat
E x c h a n g e r 110-E-03 ( h e a t i n g s y n g a s / r e c y c l e g a s a g a i n s t
rnethanol/recycle g a s ) , Reactor 110-D-01, Condensers
110-E-04 a n d 0 5 , a n d KO Drum 110-F-01, i n w h i c h t h e
u n c o n v e r t e d gas i s s e p a r a t e d f o r r e c y c l i n g .

The h i g h p r e s s u r e m e t h a n o l l i q u i d i s exDanded i n t o
E x p a n s i o n Vessel 110-F-03 f o r d e g a s s i n g ; t h e m e t h a n o l
is s e n t t o Methanol Conversion U n i t 150.
The e x p a n s i o n gas o f 110-F-03 i s r e c o m p r e s s e d i n H a
R e c o v e r y U n i t 111 a n d s e n t t o M e t h a n a t i o n U n i t 1 1 2 .

-42-
 To eliminate the concentration of inerts in the
recycle gas, a portion of the recycle gas is purged
continuously and fed to Methanation Unit 112.
6llJ
3.4.12 H2 Recovery Unit 111 (PFD ZO-GEM-6908)
Purpose of the Unit is to recover hydrogen for
hydrotreating the gasifier naphtha. The hydrogen
source is a slip stream from the methanol unit-
purge gas.
Technology Used
Because of the relatively high C02 content of the
feedgas, the Pressure Swing Process of Union Carbide
Corp. i s used.
Process DescriDtion
The main equipment of the unit are four parallel
pressure-swing absorbers, 111-D-01; one is in
operation and three are in regeneration. During
operation, essentially all of the non-hydrogen
components and a portion of the hydrogen are absorbed.
The remaining hydrogen leaves the absorber at a
purity of over 98%.
Regeneration is by pressure reduction in 3-stages
with the final pressure being nearly atmospheric.
The regeneration cycle is controlled automatically
by motor values. An absorption/regeneration cycle
requires several minutes.
The desorbed gases, called pressure-swing offgases,
are recompressed by Compressor 111-c-01 back into
the methanol unit purge gas stream before being changed
to Methanation Unit 112. Gas H o l d e r 111-F-01 on t h e
suction side of the compressor, is necessary for
buffering the non-static, pressure-swing off gas flow
f r o m the regenerating absorbers. Compressor 111-C-01
also recompresses the expansion gas from Unit 110.
3.4.13 Methanation Unit 112 (PFD ZO-GEM-6906)
Purpose of the Unit is the production of SNG meeting
the specifications for compatibility with existing
pipeline gases. In addition, the CO content must be
lowered to less than 0.1%.

-43-
- -

The p r i n c i p a l r e a c t i o n s i n m e t h a n a t i o n a r e d e s c r i b e d
by t h e f o l l o w i n g e q u a t i o n s :

C02 + 4 H2 LCH4 + 2 H 2 0 exothermic

CO + 3 H2 \CH4 + H20 exothermic
&
CO + H 2 0 -C02 + H2

O t h e r m i n o r r e a c t i o n s i n c l u d e t h e h y d r o g e n a t i o n of
e t h y l e n e t o e t h a n e and t h e c r a c k i n g o f e t h a n e t o
methane.

T e c h n o l o g y Used

The L u r g i M e t h a n a t i o n P r o c e s s i s u s e d . T h i s p r o c e s s is
t h e first p r o c e s s developed f o r t h e methanation of h i g h
CO c o n c e n t r a t i o n g a s e s , a n d h a s b e e n i n c l u d e d i n t h e
p r o p o s e d c o m m e r c i a l U.S. SNG p l a n t s .

Process Description

The f e e d g a s is made up of t h e p u r g e a n d e x p a n s i o n gases

f r o m Methanol S y n t h e s i s U n i t 110.

The m e t h a n a t i o n u n i t c o n s i s t s of two down-flow, fixed-bed

r e a c t o r s i n s e r i e s . The f e e d gas i s h e a t e d i n 1 1 2 - E - 0 6
a n d 03 a g a i n s t t h e s e c o n d r e a c t o r , 112-D-02, p r o d u c t .
Steam i s i n j e c t e d i n t h e f e e d gas a n d t h e g a s i s a l s o
d i l u t e d w i t h a p o r t i o n of t h e m e t h a n a t e d g a s f r o m t h e
f i r s t r e a c t o r , 112-D-01. The d i l u t i o n g a s i s c o m p r e s s e d
by R e c y c l e C o m p r e s s o r 112-C-01, a f t e r h a v i n g b e e n
c o o l e d i n 112-E-01 a n d 0 2 . hlP steam i s g e n e r a t e d i n
112-E-01.

The n e t r e a c t o r e f f l u e n t f r o m t h e f i r s t r e a c t o r f l o w s t o
t h e second, o r clean-up, r e a c t o r i n which f i n a l methanation
takes place. The c l e a n - u p r e a c t o r e f f l u e n t i s h e a t
exchanged aga.inst t h e f e e d and c o o l e d i n Exchangers
112-E-04 a n d 05.

P r o c e s s w a t e r c o n d e n s e d f r o m t h e r e a c t o r e f f l u e n t stream
i s c o l l e c t e d a n d r o u t e d t o BFW P r e p a r a t i o n U n i t 131.
The m e t h a n a t e d g a s l e a v e s t h e u n i t f o r f u r t h e r t r e a t i n g
i n C02 Removal U n i t 113.

-44-
3.4.14 COR Removal U n i t 113 (PFD ZO-GEM-6907)

P u r p o s e o f t h e U n i t i s t o l o w e r t h e CO2 c o n t e n t
in t h e SNG t o a b o u t 0 . 5 % , t h e r e b y i m p r o v i n g i t s
quality.

T e c h n o l o g y Used

The Amine G u a r d P r o c e s s of Union C a r b i d e C o r p . u s e s

a monoethanol a m i n e s o l u t i o n as t h e absorbant. T h i s
p r o c e s s o f f e r s b e t t e r economics t h a n a c o n v e n t i o n a l l y
d e s i g n e d MEA wash s y s t e m a n d p r o v i d e s c o m p l e t e
protection against corrosion. A MEA p r o c e s s was
c h o s e n b e c a u s e t h e s p e c i f i e d low f i n a l C02 c o n t e n t
does n o t a l l o w t h e u s e o f a h o t p o t a s s i u m c a r b o n a t e
p r o c e s s a n d t h e p a r t i a l p r e s s u r e o f C02 i n t h e f e e d
gas i s t o o low f o r e c o n o m i c a l u s e o f a p h y s i c a l
a b s o r p t i o n p r o c e s s , s u c h as R e c t i s o l .

Process D e s c r i p t i o n

The M e t h a n a t i o n U n i t 112 p r o d u c t g a s a n d t h e o f f g a s e s
o f F r a c t i o n a t i o n U n i t 152 a r e c h a r g e d t o A b s o r b e r
113-D-01 i n w h i c h t h e C02 i s washed o u t by c o u n t e r -
c u r r e n t f l o w w i t h l e a n MEA s o l u t i o n . I n t h e t o p of
t h e a b s o r b e r , t h e g a s is scrubbed w i t h a small flow
of BFW t o r e c o v e r t r a c e a m o u n t s o f MEA. The p u r i f i e d
gas t h e n f l o w s t o S N G D r y i n g U n i t 1 1 4 .

The a b s o r b e r b o t t o m s p r o d u c t ( r i c h MEA s o l u t i o n ) i s
e x p a n d e d a f t e r h e a t e x c h a n g e i n 1 1 3 - E - 0 1 i n t o MEA
R e g e n e r a t o r 1 1 3 - D - 0 2 > w h e r e t h e C02 a n d o t h e r c o - a b s o r b e d
compounds a r e s t r i p p e d f r o m t h e MEA s o l u t i o n . The
steam i n t h e r e g e n e r a t o r o v e r h e a d i s c o n d e n s e d i n
C o n d e n s e r s 113-E-04 a n d 0 5 , a n d t h e r e m a i n i n g o f f g a s e s
a r e s e n t t o B o i l e r U n i t 122 f o r i n c i n e r a t i o n . The
s t e a m c o n d e n s a t e i s r e f l u x e d t o t h e t o p of t h e
regenerator. The l e a n s o l u t i o n f r o m t h e b o t t o m of t h e
r e g e n e r a t o r i s pumped b a c k t o t h e A b s o r b e r 113-D-01,
a f t e r b e i n g c o o l e d i n 1 1 3 - E - 0 1 , 02 a n d 03.
The o f f g a s e s o f F r a c t i o n a t i o n U n i t 152 a r e c o m p r e s s e d
t o t h e SNG p r e s s u r e by L i g h t G a s C o m p r e s s o r 1 1 3 - C - 0 1 .
A f t e r c o m p r e s s i o n , t h e gas i s cooled a n d t h e h e a v i e r
h y d r o c a r b o n s , w h i c h c o n d e n s e , a r e r e t u r n e d t o U n i t 152.

-45-
3.4.15 SNG D r y i n g U n i t 114 (PFD ZO-GEM-6907)
P u r p o s e o f t h e U n i t i s t o d r y t h e w e t SNG t o a water
c o n t e n t o f 4 lb/MhISCF b e f o r e i t s i n t r o d u c t i o n i n t o
t h e SNG p i p e l i n e s y s t e m .

-
T e c h n o l o g y Used

The TEG Wash P r o c e s s , a c o m m e r c i a l p r o c e s s f o r d r y i n g

n a t u r a l g a s , is used.

Process Description

The d r y i n g a g e n t i s a m i x t u r e o f t r i e t h y l e n e g l y c o l
(TEG) a n d o t h e r e t h y l e n e g l y c o l s .

The SNG i s c o n t a c t e d c o u n t e r c u r r e n t l y i n Water A b s o r b e r

114-D-01 w i t h l e a n TEG. T h e w a t e r - r i c h TEG f l o w s
from t h e a b s o r b e r t o TEG R e g e n e r a t o r 114-D-02, which
i s h e a t e d by f u e l q a s . The steam s t r i p p e d f r o m t h e
TEG i s d i s c h a r g e d t o t h e a t m o s p h e r e . The s m a l l r e f l u x
stream r e q u i r e d i s c o n d e n s e d w i t h i n t h e v e n t t u b e by
air cooling.
The r e g e n e r a t e d TEG i s s t o r e d i n 114-F-01, w h e r e i t
i s c o o l e d by t h e r i c h TEG, b e f o r e b e i n g pumped i n t o
t h e t o p of Water A b s o r b e r 1 1 4 - D - 0 1 .

3.4.16 M e t h a n o l C o n v e r s i o n U n i t 150 (PFD ZO-GEM-6915)

P u r p o s e of t h e U n i t i s t o d e h y d r a t e c r u d e m e t h a n o l t o
LPG a n d g a s o l i n e h y d r o c a r b o n s w h i c h c a n b e m a r k e t e d
d i r e c t l y without f u r t h e r processing.

T e c h n o l o g y Used

Mobil h a s d e m o n s t r a t e d a s i m p l e c a t a l y t i c p r o c e s s t o
d e h y d r a t e m e t h a n o l t o t h e s t o i c h i o m e t r i c y i e l d of
h y d r o c a r b o n s ( 4 4 % ) a n d water ( 5 6 % ) .

x CH30H 4(CH2)x $- H20

T h i s d e v e l o p m e n t h a s b e e n r e p o r t e d u n d e r ERDA C o n t r a c t
N o . E(49-18)-1773, and i n r e f e r e n c e s c i t e d . The
hydrocarbons are predominately i n t h e g a s o l i n e b o i l i n g
r a n g e (C4 t o Clo), a n d t h e g a s o l i n e i s c h e m i c a l l y
c o n v e n t i o n a l c o n s i s t i n g of h i g h l y b r a n c h e d p a r a f f i n s
(51%), h i g h l y b r a n c h e d o l e f i n s ( 1 3 % ) , n a p h t h e n e s ( 8 % )
a n d aromatics ( 2 8 % ) . I t s u n l e a d e d r e s e a r c h o c t a n e
number (RON) r a n g e s f r o m 90 t o 100. E s s e n t i a l l y , n o
h y d r o c a r b o n s l a r g e r t h a n C 1 o a n d no o x y g e n a t e s a r e p r o d u c e d .

-46-
S m a l l a m o u n t s o f CO, C02 a n d c o k e a n d t r a c e a m o u n t s
of formic a c i d a n d a c e t o n e i n t h e water p r o d u c t a r e
formed as by-products. A f t e r f o u r t e e n d a y s on s t r e a m ,
enough c o k e a c c u m u l a t e s on t h e c a t a l y s t t o r e q u i r e
r e g e n e r a t i o n . The c a t a l y s t i s r e g e n e r a t e d b y c o k e
combustion i n a c o n t r o l l e d manner t o l i m i t t h e maximum
t e m p e r a t u r e t o 90O0F. Since the catalyst converts
o t h e r o x y g e n a t e s and is t o l e r a n t t o water, c r u d e
methanol w i t h o u t any p u r i f i c a t i o n can be c h a r g e d
d i r e c t l y , t h e r e b y s i m p l i f y i n g t h e methanol s y n t h e s i s .

From l a b o r a t o r y i n v e s t i g a t i o n s , t h e r e a c t i o n p a t h from
methanol t o hydrocarbons a p p e a r s t o be reasonably w e l l

2 CH30H -
r e p r e s e n t e d by :

-H20

+H20
CH30CH3
-H20 = = paraffins
~ 2 - ~ 5 aromatics
cycloparaffins

alcohol ether olefin

The r e a c t i o n i s h i g h l y e x o t h e r m i c w i t h t h e h e a t o f r e a c t i o n
b e i n g a b o u t 740 B t u / l b o f m e t h a n o l . T h e r e f o r e , t h e
p r i n c i p a l problem i n d e s i g n i n g a reactor system is
heat removal. I n t h e f i x e d bed reactor system, t h i s problem
i s m i n i m i z e d by d i v i d i n g t h e a b o v e o v e r a l l r e a c t i o n
( a n d r e a c t o r s y s t e m ) i n t o two s t e p s . In t h e f i r s t ,
methanol is p a r t i a l l y dehydrogenated t o form an e q u i l i b r i u m
m i x t u r e o f m e t h a n o l , d i m e t h y l e t h e r a n d w a t e r . About
20% of t h e h e a t o f r e a c t i o n i s r e l e a s e d i n t h i s f i r s t
s t e p w i t h o u t any r e c y c l e f o r t e m p e r a t u r e c o n t r o l . In
t h e second s t e p , where hydrocarbon c o n v e r s i o n t a k e s p l a c e ,
a l a r g e r e c y c l e g a s stream ( f r o m 6 / 1 t o 9/1 r a t i o ) i s
used t o l i m i t t h e temperature rise across t h e bed t o
a b o u t 125OF.
While o t h e r s y s t e m s , s u c h as quenched r e a c t o r , t u b u l a r
h e a t e x c h a n g e r e a c t o r , o r f l u i d i z e d bed r e a c t o r c o u l d
be d e s i g n e d , t h e f i x e d b e d , g a s r e c y c l e s y s t e m h a s b e e n
w e l l demonstrated and is r e a d i l y scaleable t o h i g h e r
throughputs.

The commercial p r o c e s s d e s i g n c o n d i t i o n s , y i e l d s a n d
c a t a l y s t p r o p e r t i e s u s e d i n t h i s s t u d y a r e shown i n
Tables 3 . 4 . 1 , 3.4.2 and 3 . 4 . 3 , r e s p e c t i v e l y . These d a t a
were d e v e l o p e d from ERDA C o n t r a c t N o . E(49-18)-1773 a n d
r e p r e s e n t t h e b e s t estimate a t t h i s t i m e of a commercial
f i x e d bed o p e r a t i o n .

-47-
 TABLE 3.4.1
PROCESS DESIGN CONDITIONS FOR FIXED BED n
METHANOL CONVERSION UNIT 150

I. Nominal Operating Conditions

Feed Composition (See Material Balance Stream 37.)
Methanol 18,360.3 lb. mol/hr.
Water 1,382.4 lb. mol/hr.
Others . 42.5 lb. moljhr.
19,785.2lb. mol/hr. (52,585 B/SD)
Base Yields (See following Table 3.4.2.)*
Reactor Conditions
First Reactors (DME)
Pressure, Inlet 315 psig
Temperature, Inlet 566OF
Temperature, Outlet '768OF
Space Velocity 6 lb. fresh feed/hr/lb.
catalyst
Catalyst Mobil first stage catalyst
Estimated Ultimate Catalyst
Life 1 year
Second Reactors (M-Gasoline)
Pressure, Inlet 300 psig
Temperature, Inlet 625OF
Temperature, Outlet '752OF
Space Velocity 1.84 lb. fresh feed/hr/lb.
catalyst
Molar Recycle Ratio 7.5/1 (based on fresh feed)
Cata1yst Mobil second stage catalyst
Estimated On-Stream Time
Before Regeneration 14 days
Estimated Ultimate Catalyst
Life 1 year
11. Regeneration Conditions
Aged Catalyst Coke Level (Second Reactors) 30 wt. on
catalyst (Controlled oxygen content and controlled maximum
temperature procedure similar to conventional petroleum
naphtha pretreater/reformer regeneration is employed.)

-48-
 TABLE 3.4.1 ( c o n t i n u e d )

TII. Metallurgy

The b a s i c m e t a l l u r g y f o r t h e M e t h a n o l C o n v e r s i o n U n i t 150
is c a r b o n s t e e l . Reactors h a v e a 304SS i n t e r n a l l i n e r
o v e r 3" of r e f r a c t o r y t o m i n i m i z e t h e e f f e c t s of a n y
p o s s i b l e t e m p e r a t u r e e x c u r s i o n s . The h i g h p r e s s u r e
s e p a r a t o r , 150-F-01 i n p r o c e s s f l o w d i a g r a m ZO-GEM-6915,
h a s a PVC l i n i n g t o p r o t e c t a g a i n s t t h e a c i d water ( p H = 3 . 5 ) .
The t u b e s of E x c h a n g e r s 150-E-01, 06 a n d 07 a r e 316SS
t o p r o t e c t from a c i d water c o r r o s i o n . I n a d d i t i o n , t h e
s h e l l of E x c h a n g e r 1 5 0 - E - 0 1 i s c a r b o n s t e e l w i t h
316SS l i n i n g . The a c i d water l i n e s a r e PVC l i n e d .

* Y i e l d s a r e t h e a v e r a g e o v e r 1 4 d a y s of o p e r a t i o n b e f o r e c a t a l y s t
r e g e n e r a t i o n . Although y i e l d s h i f t s are s i g n i f i c a n t d u r i n g t h e
1 4 d a y s ( s e e R e f e r e n c e 2 ) , t h e 5-reactor s y s t e m , U n i t 150 d e s i g n
basis, minimizes t h e y i e l d s h i f t effects.

-49-
 TABLE 3.4.2
METHANOL CONVERSION UNIT 150
BASE FEED AND PRODUCT COMPOSITION
(Basis: 100 Lb-Mole A!ethanol in Feed)

Component Names Feed Product

Coke (as CH0.8) .ooo .128

Acetone .ooo .129
Formic Acid .ooo .163
Met hano1 100.000 .ooo
Dimethylether .ooo .ooo
Water 7.529 106.951
Carbon Monoxide .ooo .017
Carbon Dioxide .ooo .053
Hydrogen ,000 .040
Me thane .ooo .746
Ethane .000 .193
Ethene .ooo .018
Propane .ooo 1.474
Propene .ooo .064
N-Butane .ooo .665
I-Butane .000 2.155
Butenes .ooo .270
N-Pentane .ooo .268
I-Pentanes .ooo 2.353
Pentenes .ooo .435
Cyclopentane .000 .047
Methylcyclopentane .ooo .214
N-Hexane * 000 .113
I-Hexanes * 000 1.991
Hexenes .ooo .297
Methylcyclohexane .000 .062
N-Heptane .000 .026
I-Heptanes ,000 .786
Heptenes .ooo .292
1,3-Dicyclopentane, cis .ooo .233
I-Octanes .000 .228
Octenes .ooo .301
N-Propylcyclopentane .ooo .299
N-Nonane ,000 ,015
I-Nonanes .ooo .084
Nonenes .000 .116
N-Butylcyclopentane .ooo .071
I-Decanes .ooo .024
Decenes .ooo .045
Benzene .ooo .036
Toluene .ooo .280
Ethylbenzene .ooo .070
m- + p-Xylenes .ooo .876
o-Xy 1ene .000 .240
1,2,4-Trimethylbenzene .ooo .818
1,3,5-Trimethylbenzene .ooo .034

-50-
 TABLE 3.4.2 (continued)

Component Names Feed Product

P-Ethyltoluene .ooo .292

I-Propylbenzene .ooo .014
1,2,4,5-Tetramethylbenzene .ooo .436
1,2,3,5-Tetramethylbenzene .ooo .063
1,2,3,4-Tetramethylbenzene .ooo .023
p-Diethylbenzene .ooo .198
Penta-Methylbenzene .ooo .068
2-Methylnaphthalene .ooo .017
Total Lb-Mole 107.529 124.832
Weight (lbs) 3,339.846 3,339.846

-51-
 TABLE 3.4.3

METHANOL CONVERSION UNIT 150

CATALYST PROPERTIES n

-------Mobil Catalysts-------

First S t a g e Second S t a g e

Type Extrudate Extrudate

Geometry 1/16" x 3/16" 1/16" x 3/16"

Bulk D e n s i t y 35 l b / c u f t 36 l b / c u f t

Crush S t r e n g t h 50 l b / i n 33 l b / i n

cost * *

* S i n c e Mobil h a s no s p e c i f i c commercial e x p e r i e n c e i n m a k i n g
t h e s e c o n d s t a g e c a t a l y s t i n t h e a m o u n t s r e q u i r e d f o r a major
s y n f u e l s i n d u s t r y , a n a c c u r a t e c o s t c a n n o t be g i v e n a t this
time. W e are s u r e , however, t h a t i t s cost w i l l c o n t r i b u t e
o n l y a minor p o r t i o n t o t h e t o t a l g a s o l i n e cost and, t h e r e f o r e ,
i t s a d d i t i o n a t a l a t e r t i m e w i l l n o t a l t e r any c u r r e n t economic
evaluation study conclusions.

-52-
Process DescriDtion
Depressured crude methanol, pumped (150-G-01) to
reaction pressure and vaporized in Heat Exchangers
150-E-01 and 02, flows to DhlE Reactor 150-D-01,
where it is catalytically converted to an equilibrium
mixture of methanol, dimethylether and water. Inlet
operating conditions are 315 psig and 5660F.
The equilibrium mixture then flows to the M-Gasoline
reactors (150-D-02), of which five are operating
and one is undergoing regeneration. A gas recycle
stream from Separator 150-F-01, after compression
(150-C-01) and heat exchanged (150-E-04 and 05)
against the reactor effluent, is fed along with the
equilibrium mixture into the M-Gasoline reactors.
The recycle stream controls the temperature rise.
Its temperature is maintained to give a reactor
inlet temperature of 625OF.
Cooling of Reactor 150-D-02 effluent occurs as
follows: (1) Steam Generator 159-E-03, (2) the
recycle stream and methanol feed heat exchangers,
(3) BFW Heat Exchanger 150-E-06 and (4) Air Trim
Cooler 150-E-07. Separator 150-F-01 operating
conditions are 248 psig and 155OF. The purge gas
flow is limited to that only required for control.
The liquid hydrocarbon product is pumped (150-G-02)
to Unit 152. A small amount, five gpm, of hydrocarbon
product is recycled from the separator to the
inlet of BFW Exchanger 150-E-06 for durene crystalli-
zation control.
Regeneration of the >$-Gasoline reactors takes place
about once every 14 days. After a reactor is taken
off line, it is depressured and purged with nitrogen
until there is less than about 1 to 5 vol. % of
hydrocarbons present. Then the reactor is pressured
to about 150 gsig with nitrogen flow through Recycle
Compressor 150-C-02. The temperature is maintained
at 650°F by use of Furnace 150-B-01. Air is introduced
slowly until oxygen content reaches about 1 vol. %.
The maximum catalyst bed temperature is maintained
at less than 850OF. \\'hen the oxygen content in the
recycle gas becomes higher than 0.1 vol. %, the inlet
temperature is slowly raised while maintaining a
maximum temperature of 900°F in the bed. The hot
spent regeneration gas is cooled by heat exchange with
the fresh regeneration gas (150-E-08) and Fan Cooler
150-E-09. Condensed water is removed via Drum 150-F-02.

-53-
3.4.17 Naphtha H y d r o t r e a t i n g U n i t 151 (PFD ZO-GEM-6908)

Purpose of t h e Unit is t o o b t a i n a c l e a n , odor f r e e ,

s t a b l e material from t h e r a w g a s i f i e r n a p h t h a f o r n
gasoline pool blending. Reaction c o n d i t i o n s chosen
w i l l s u b s t a n t i a l l y s a t u r a t e t h e r a w naphtha o l e f i n s
with l i t t l e aromatic-ring hydrogenation, thereby
reducing t h e octane r a t i n g as l i t t l e as p o s s i b l e .

T e c h n o l o g y Used

H y d r o t r e a t i n g is a v e r s a t i l e p r o c e s s i n which t h e
q u a l i t y o f a wide v a r i e t y of p e t r o l e u m materials
can b e improved w i t h t h e p r o p e r c h o i c e o f c a t a l y s t
and o p e r a t i n g c o n d i t i o n s . I t i s u s e d commercially
t o remove i m p u r i t i e s s u c h a s s u l f u r , n i t r o g e n a n d
oxygen, t o s a t u r a t e o l e f i n i c double-bonds and t o
improve t h e odor, c o l o r , s t a b i l i t y and b u r n i n g
characteristics. G e n e r a l l y , c a t a l y s t s and c o n d i t i o n s
employed r e s u l t i n a s l i t t l e as p o s s i b l e c a r b o n -
bond c r a c k i n g . P r e s s u r e s range f r o m 200 t o 1 , 0 0 0 p s i g ,
a n d t e m p e r a t u r e s f r o m 400 t o 750°F. Typical l i q u i d
h o u r l y s p a c e v e l o c i t i e s a r e f r o m 1 t o 10 volume o f
o i l p e r h o u r p e r volume of c a t a l y s t . H y d r o g e n - r i c h
g a s r e c y c l e may o r may n o t b e u s e d d e p e n d i n g upon
t h e s e v e r i t y of o p e r a t i o n . S i n c e h y d r o g e n a t i o n
r e a c t i o n s are exothermic, multi-bed r e a c t o r s w i t h a
hydrogen recycle quench are u s e d t o c o n t r o 1 , r e a c t o r
t e m p e r a t u r e s when t h e h y d r o g e n c o n s u m p t i o n i s l a r g e .
A l a r g e number o f c a t a l y s t s h a v e b e e n d e v e l o p e d .
Various colbalt-molybdena c a t a l y s t s w i t h alumina
s u p p o r t s ; however, a c c o u n t f o r t h e b u l k of t h e a p p l i c a t i o n s .
T h i s c a t a l y s t i s oxygen r e g e n e r a b l e , a n d q u i t e r u g g e d
i n n a t u r e . Commercial p r o c e s s e s a r e l i c e n s e d by BP
T r a d i n g , I F P , Exxon, G u l f , S h e l l , Union O i l a n d
Standard O i l (Indiana).

Process Description

The r a w n a p h t h a i s pumped ( 1 5 1 - G - 0 1 ) to reactor

p r e s s u r e , h e a t exchanged w i t h t h e r e a c t o r e f f l u e n t
i n Exchanger 151-E-01, h e a t e d t o r e a c t o r t e m p e r a t u r e
i n F i r e d Heater 1 5 1 - B - 0 1 , a n d c h a r g e d t o R e a c t o r
151-D-01. A p o r t i o n o f t h e h y d r o g e n f e e d i s mixed
and h e a t e d w i t h t h e naphtha; t h e remainder is used
a s a c o l d quench f o r t e m p e r a t u r e c o n t r o l i n t h e m u l t i -
b e d r e a c t o r . The r e a c t o r e f f l u e n t i s f u r t h e r c o o l e d
( 1 5 1 - E - 0 2 a n d 0 3 ) b e f o r e f l u s h i n g i n S e p a r a t o r 151-F-01.
A s m a l l BFW f l u s h i n g stream is a d d e d b e f o r e 1 5 1 - E - 0 1 .

-54-
 The h y d r o g e n - r i c h v a p o r p a s s e s f i r s t t h r o u g h a n
amine tower f o r hydrogen s u l f i d e c o n t r o l , and t h e n
s p l i t i n t o r e c y c l e a n d p u r g e g a s streams. The
p u r g e gas i s i n c i n e r a t e d i n B o i l e r U n i t 1 2 2 . A f t e r
c o m p r e s s i n g (151-C-01), t h e recycle a n d h y d r o g e n
make-up a r e combined b e f o r e s e p a r a t i n g i n t o t h e
h y d r o g e n f e e d a n d q u e n c h streams.

The s e p a r a t o r l i q u i d p r o d u c t i s c h a r g e d t o S t a b i l i z e r
151-D-05. The l i g h t g a s / h y d r o g e n s u l f i d e o v e r h e a d
p r o d u c t s a r e s e n t t o S u l f u r R e c o v e r y U n i t 106.
Condensed A c c u m u l a t o r 151-F-03 l i q u i d s a r e r e f l u x e d .
C o o l e d (151-E-06 a n d 0 7 ) s t a b i l i z e d n a p h t h a i s s e n t
t o o f f s i t e B l e n d i n g U n i t 1 5 4 . A s m a l l s o u r water
stream i s a l s o o b t a i n e d f r o m S e p a r a t o r 151-F-01.

R e g e n e r a t i o n s y s t e m s are p r o v i d e d f o r R e a c t o r 1 5 1 - D - 0 1
a n d t h e r i c h a m i n e s o l u t i o n f r o m A b s o r b e r 151-D-02.

3.4.18 F r a c t i o n a t i o n U n i t 152 (PFD Z O - G E M - 6 9 1 6 )

P u r p o s e of t h e U n i t i s t o o b t a i n a l o w C2 c o n c e n t r a t i o n
a l k y l a t e u n i t c h a r g e and a s t a b i l i z e d g a s o l i n e f o r
pool blending.

Process D e s c r i p t i o n

The h i g h p r e s s u r e c o n d e n s a t e (stream 58) f r o m t h e S N G

t r a i n i s f l a s h e d i n Drum 150-F-01. The d e p r e s s u r e d
l i q u i d and t h e hydrocarbon p r o d u c t from U n i t 150 are
f e d t o D e e t h a n i z e r 152-D-01. The e t h a n e - r i c h
tower o v e r h e a d a n d t h e f l a s h drum v a p o r s a r e s e n t t o
U n i t 113 i n t h e S N G t r a i n . The d e e t h a n i z e r b o t t o m s
after being cooled i n Deethanizer Side Reboiler
152-E-02 i s f e d t o S t a b i l i z e r 152-D-02. Products are
c o o l e d a l k y l a t i o n f e e d (overhead) and s t a b i l i z e d
g a s o l i n e ( b o t t o m s ) . B o t h towers e m p l o y steam r e b o i l e r s
(152-E-01 a n d 0 5 ) .

3.4.19 A l k y l a t i o n U n i t 153 (PFD ZO-GEM-6916)

P u r p o s e o f t h e U n i t i s t o increase t h e g a s o l i n e y i e l d
by t h e r e a c t i o n b e t w e e n i s o - b u t a n e a n d b u t e n e / p r o p e n e
a n d t o y i e l d commercial g r a d e p r o p a n e a n d b u t a n e
l i q u i f i e d petroleum gases.

-55-
T e c h n o l o g y Used

A l k y l a t i o n , i n p e t r o l e u m r e f i r l n g , n o r m a l l y means t h e
r e a c t i o n of b u t e n e a n d / o r p r o j e n e w i t h i s o - b u t a n e
t o p r o d u c e a h i g h e r m o l e c u l a L *w e i g h t i s o - p a r a f f i n .
For example:

i-Butane n-Butene i-0ct a n e

Alkylation can occur without c a t a l y s t s , but commercially,

acid c a t a l y s t s are used w i t h s u l f u r i c acid and hydrogen
f l o u r i d e b e i n g t h e t w o most i m p o r t a n t . Unlike t h e
s i m p l e r e a c t i o n a b o v e , a m i x t u r e of isomers i s o b t a i n e d .
I n a d d i t i o n , p o l y m e r i z a t i o n o c c u r s , and "sludge" is
yielded requiring catalyst regeneration. Alkylation,
h i g h l y e x o t h e r m i c , l i b e r a t e s 600 t o 700 B t u / l b o f
iso-butane. C o m m e r c i a l p r o c e s s e s a r e l i c e n s e d by
P h i l l i p s P e t r o l e u m , UOP P r o c e s s a n d S t r e t f o r d E n g i n e e r i n g .

Process Description

The i s o - b u t a n e j o l e f i n f r e s h feed i s f i r s t m i x e d w i t h
t h e c o o l e d HF a c i d / i s o - b u t a n e r e c y c l e streams ( 1 5 3 - E - 1 6 ) ,
a n d t h e n , t h i s m i x t u r e is c h a r g e d t o t h e combined
R e a c t o r / S e t t l e r 153-D-01. The r e a c t o r e f f l u e n t - i n e r t
hydrocarbons, excess iso-butane and a l k y l a t e - after
h e a t i n g (153-E-01 and 0 2 ) i s f e d t o D e i s o b u t a n i z e r
153-D-02. P r o d u c t s a r e a C3/i-C4 o v e r h e a d , m i x e d - b u t a n e s
side-cut and a l k y l a t e bottoms. The o v e r h e a d m i x t u r e ,
a f t e r c o n d e n s i n g i n C o n d e n s e r s 1 5 3 - E - 0 8 and 0 9 , i s
pumped (153-G-01) i n t o D e p r o p a n i z e r 153-D-03 f o r
s e p a r a t i o n i n t o t h e C 3 LPG p r o d u c t a n d e x c e s s i s o - b u t a n e
recycle.

The h y d r o g e n f l u o r i d e is r e c y c l e d from R e a c t o r / S e t t l e r
153-D-01. A c o n t i n u o u s s l i p stream from t h e a c i d r e c y c l e
is p u r i f i e d i n a c o n v e n t i o n a l HF r e r u n u n i t ( n o t shown).
N o t shown on t h e s i m p l i f i e d p r o c e s s f l o w d i a g r a m a r e a
HF s t r i p p e r i n t h e C 3 LPG stream a n d c a u s t i c w a s h e s
i n t h e p r o d u c t streams t o remove a l l t r a c e s of a c i d .

-56-
-3.4.20
/
U n i t C a p a c i t y Summary
J
The c a p a c i t i e s of t h e p r i n c i p a l p r o c e s s u n i t s have
been summarized below i n $ c o n v e n t i o n a l f l o w r a t e s :
---Capacity, Unit/SD--
U n i t No. Name Input output

101 Gasification 22.8 MT c o a l 1,755 MMSCF

102 Raw G a s S h i f t 331 MMSCF -
105 G a s Purification 1,062 MMSCF 742 MMSCF
110 Methanol. S y n t h e s i s 742 MMSCF 5 3 . 3 M Bbl
150 Methanol Conversion 52.6 M Bbl 2 5 . 7 M Bbl
151 Naphtha H y d r o t r e a t i n g 1.3 M Bbl -
152 Fractionation 25.7 M Bbl -
153 Alky 1a t i o n 5.3 M Bbl ( 7 5 0 Bbl/SD a l k y l a t e )
SNG T r a i n 213 MMSCF 148 MMSCF

-57-
 i
E'8L + S'LL L'SEZ + i P.992 + ED +
I
S'Z - C.9696 +
L'S +
I I
I Ill
9'8 +
I
! I I I
I I I '
L'OPL +
t r - t I I
S'SZ +
8'LLZ 2 -
L. 0
6
l V O 3 31111 J!V
9'20 1
B'LBLS -
 W L L X E D co4L f 695
FROM C W W D L FRO (as r n L
WIT 128 IO 3

Q !

. . 4
H"P-LCCK ~ 4 s
TO RECOMPRESSION SECTION I TASN GAS LlOU RECYCLE
FROM RAW GAS COOLING
UNIT 1 0 1 I UNIT 103
<
m U-
EMERGENCY INJECTION WATER
L.P LOCK CAS FROM UNIT 107
TO RECOMPRESSION SECTION
UNIT 101

TO GASIFICATION FLARE SYSTEM

101-E-OL 101-F-OL
101-c-01
I

"t
F
EXAUST GAS
TO ATMOSPHERE
GAS L I O U
TO APl - P I T

RAW GbS
TO RAW GAS COMING
UNIT 103
C W - B L O W DOWN
101-F-05

I
101-D-02
WASTE WATER
TO A S H HANDLING 101-G-03
UNIT 1 2 9

w 1 0 0 PSIG S T E A M

M P - BF.W
4 I1 101-E-01
I I
\r LP-BFW

101-E-03

OXYGEN
FROM CFlGEN PROWCT,
UNIT 121
ACCOMPANYING DRAWING
2.0-GEM-6896 RECOMPRESSION SECTION

-
101- F-02 OF U N I T 101

A 1
\*/v
M P-STEAM SUF'ERHEATEO NOTES
STREAMS WITHOUT STREAM NUMBERS
ARE NOT INCLUDED IN THE OVERALL
MATERIAL BALANCE
t 7
THIS PFO IS IOENTICAL FOR BASE CASE I A N 0 11
DUSTY GAS LIQUOR
TO GAS LIOUOR SEPARATION
UNIT 107

7
ASH 1. SLU E WATER WE w R WCLE
mM WNXM FROM A HANDLlNj
m 129 m 129
-59
I
m
0
I

f
 x
(?
N
-I
I
0
I
N
0
E’
+-’ e
I
IA
x5
 r

YI

s
I
W
6
W
?
F 0
W

0
W r

' t, I !
L
 INJECT
mol
LP ww sm
VIY

i)
104- F-03 ) 1OL- F- 04

SHFTEO GAS
FRCU R W U
UNIT 102
S SHIFT

f
i

c
f
r
104-C-01 i

104-E-03

1 104- F- 01
TO G A S FWfIFTATIOI(
,

WTES
M
1%Y PFO
C A YIS I IDENTICAL
AN0 II FOC

STREAMS W l I H O U I S T R E A M N U M M R S
ARE NOT INCLUDED IN T M E OVERALL
MAIERIAL BALANCE

OLY ms
LO COOCEl A S LIO
m MS ~ n YRIIATCU
a ~ TO us Lia SERRATION
WIT 107 LNI
37 -63-
 m

m
sg
o
omr

IT

I
f I
2
cn 0
c
I
L...
I J G m c:
?
0
8 m

-I - -- .-

I
%
i
3
0
>

B
3
i
 1 I
I
I,
i
3 f

106-GO1

0
UNIT 122

106-D-I I

OFF M S
FROM O A S LlOUOR SEPARATION
UNIT 107 I

'
ACID OAS
FROM PHENOL RECOVERY
UNIT IW

ACID OAS
&J
FROM OAS PURIFICATION
UNIT 105
27
106-F702

ni-1
*
106-G-02
106-F-03

3
106-E-02

Q
P 106-F-04
106-G-04

.3 &*
OFF OAS
FROM WPHTW HYW)OTREATIW
UNIT 151
L
106-DO2

-65-
 OILY Gsis LIO u\ -10 WASTE WATER
asl 4 LIO mo FROM CTISOL FROH m N I A E C O V
FRM ~ i o i mm 3 ATM UN 104 UN 10s UNIT 109

& &
7

1165362
155715
c
i'
7-

t Xn-D-01
107-Y-01 107-FO 2

a T
107-F-02

P
VJ7.F-11

107- F-04
107-E- 03

7 107-E-OL *

IZ'

,*'
65
18

.1
. .. .. . . ..
17-r-13 HZS "6NT 1.0 mu"

TO A f l PIT
107-F-12 t I mwi PIT
107-F-12

L-
1 - ~

' I : I
107-G-01

-(7 10 7- F- 07

II
1 102F-13

107-F-10
c
107-F-09
NOTES~~

STREAMS WITHOUT STREAM NUMBERS

ARE N O T INCLUDED IN T H E OVERALL

)$
MATERIAL BALANCE

THIS PFD I S I E N T I C A L FOR mASE CASE I AND 11

107%-01

1 59851 5 9

r* R Us1 us LlOUoR
TO 831LER F R U RI m MNOL RECOV.
UNIT 122 OF\ WIT 1Q

I
I
 ACID U S
VENT T O ToWLpHRmixRy
ATMFRLRE UNIT lo6

1
T
I-
108-D-03
A I
WASTE WATE
G:
FROM AMMONIA RECOVER
UNIT 10

J L
I I I
108-G-04 1 . 0
1 . 0
A C I D GA
FROM AMMONIA RECOVER 1 . 0
1 . 0
UNIT'I 1 . 0
M U 0 LIOUOR 1 .. 00
L
TO CAS LDMR SEFAAATION 108-F-06
UNIT 107

I
1 . 0
Y . I
@ I . "
I .f "0

108-G-05
I
2 . "
2 . "
. 0

I . "
I . "
1 . 00

AMMONIA WATER
TO AMMONIA R C W E R V L.
UNIT 109 I .
I .
2I ..

I ,,r
2 .
I .
I .

II .
.

MOTES
SlRfAMS WITHOUT STRfAM WMI*RS

ARE MOT I N C L W f O IN T M OVERALL

MATERIAL I A L A N C E

THIS F T O IS IDENTICAL FOR BASE CASE 1 AND 11

IWENOSOLVAN UNIT1

-67-
J

I
 x
h)

T
5:

I
o\
03
I

I Y i i

3
2
h)

0
(D
 >2 .2
4 : % 6
k
e
i
E
L 1
N
0
<
7
m
s
4(
c
&i
c
i)
 F R O M n2 ~ E C O V E R Y
UNIT 111

i
112-D-02

112-€42
4
11 2-F-01

4
- -
112-F-02
112-E-04
112-F-03
i

112-E-05
112-F-04

&
TO
PRODUCT G A S
CO, R E M O V A L
UNIT 113

w FW
-70- 1
 COX OFF GAS
TO BOlLEU
UNIT lZ
L

v
4
WET SNG
TO SNG DRYING
UNIT 111

113- F-01

113- D- 01 11L 1-01

4 1 3 - E-03

d - &n
PRODUCT GAS
FROM WTHANATIOH
I 113- F - 03
UNIT 112 113- E- 02 113-E-OL 9
4
c ) 11L-E-01 I I
113-E-05
0,

I
STACKGAS

+:
10lBOlLEH

113- F- 02

113- E-01

I
I \

1lL-F-01 1I
/-
-'(
I 8.15

113-G-01

d 11L - G - 01

NOTES
STREAMS WITMOUT STREAM NUMBERS

113-F-04 I ARE NOT INCLUDED IN THE OVERALL

MATERIAL BALANCE

113-C-01

Q Q
1287 25 1 8

L l W T GAS CONDENSATE
TO FRACTIONATION
UNIT Is2
LlWT GAS
FRW FRACTIONATIW
WIT 152
t--
UNIT '13 z -71-
I

I
I
 0
<
a
0
z
0
Y
a
0
VI
0
&
0
Y
8'
51
Pz
t
PP
w
0
 4 L
-%
a
3
f
c
m
0
Lf.l
0
@
i
c
0
 LlGH >AS I
TO SN DRAIN
UNI 13
'

r
>
153- E-12

0 153-F-01

EQUIPYEM LIST

ITEM NO. NAME OPER. Af'PROX.

+ SPAIIPI.D. LENGTH T -
152-0-01 DEETHANIZER 1 o
1 + 0 6.-6'
8'-0" 105'
80'
152-0-02 STABILIZER
PROPANE L f f i 152-E-01 DEETHHINIZER REBOILER 1 + 0
153-E+OB 153-E-09 153-E-10 153-D-03 153-E-13 TO STORAGE 152-E-02 DEETHANIZER S I D E S T R E U / m M S
H.E. I * O
152-E-03 STABILIZER OVED CONDENSER I r a
152-E-04 STABILIZER O V W PRODUCT C m L E R 1 f 0
152-E-05 STABILIZER R o T r m S REBOILER 1 f 0
152-E-OB STABILIZER SIDE REglILER 1.0
I t 0
152-E-07 STABILIZER BORWS W L E R
152-E-08 STABILIZER B o T m y S TRIM CmLER 1 t 0

I ' 153-G-01

15

1:-
3 5 3 - E - 11
r A

'
53-D-02
153-E-06
153-E-03 18.261

MIXED BUTANES
TO STORAGE
152 - E-03
l + O
153-E-10
153-E-ll
1 4
+ 0
0
153-E-12 1 r o
5 656 153-E-13 1 + 0
153-E-14 1 + 0
153-E-15
I I r a
I M I X E D BUTANES 153-E-16 1 + 0
152-0-01 TO GASOLINE BLENDING
153-P-01 DEPROPANIZER REFLUX DRUM I t 0
UNIT 151
153-G-01 DEPROPANIZER FEW PUMP 1 + 1
153-G-02 DEPROPIYlZER RE?LUX PIRIP , + I
3 3 - E - 0 5
HYDROCARBON PRODUCT "
FROM METHANOL CONVERSION
UNIT 150
I I
153-G-03 BF ACID RECYCLE PIRIP

153- E-1 1

152-E-01
I
'W
I
153-GO3 153-E-15

3 - E - 0 5 0 STREAM NUMBER

PRESSURE PSlG
I
0
0
TEMPERATURE
FUOW RATE DRY GAS
OF

Ibmol/h,
/-7 FWI HATE S T E M
lllbslhi
AND LIQUIDS
<

I NOTE

STABILIZED GASOLINE
TO GASOLINE BLENDING
U N I T 154 -74-
 BASE CASE r
3.5 OFFSITE UNITS

!a n l e s s s t a t e d o t h e r w i s e , u n i t s a r e shown o n B l o c k Flow Diagram

0-GEM-6894 i n S u b - s e c t i o n 3 . 4 . I n a d d i t i o n , u n i t s s u c h as
b o i l e r s , g e n e r a t o r s a n d water t r e a t e r s a r e a l s o i n c l u d e d i n
Steam/BFW B a l a n c e ZO-GEM-6910 i n S u b - s e c t i o n 3 . 6 . The s c h e m a t i c
f l o w d i a g r a m s (SFD) a r e p l a c e d a t t h e e n d of t h i s s e c t i o n .
3.5.1 Oxygen P r o d u c t i o n U n i t 1 2 1

P u r p o s e of t h e U n i t i s t o p r o d u c e t h e oxygen r e q u i r e d
f o r t h e g a s i f i c a t i o n of t h e coal.

Description

The o x y g e n p r o d u c t i o n u n i t i s a n a i r s e p a r a t i o n u n i t
including t h e following:

- air f i l t e r
- a i r compressor
- air cooling
- c o l d box
- power r e c o v e r y t u r b i n e , i n c l u d i n g e l e c t r i c power g e n e r a t o r
- oxygen compressor
- n i t r o g e n release s t a c k
- l i q u i d n i t r o g e n s t o r a g e t a n k 5,000 f t 3 ( f o r s t a r t - u p , e t c . )
- n i t r o g e n e v a p o r a t o r , c a p a c i t y 500 l b - m o l / h r
- emergency l i q u i d a i r e v a p o r a t o r
- l i q u i d oxygen s t o r a g e t a n k

N o r m a l Capacity

Oxygen q u a n t i t y ( c a l c u l a t e d a s 100%): 14,060 lb-mol/hr

Oxygen p u r i t y : 98.06%

Design Capacity 105% of n o r m a l

Note: I n a d d i t i o n , 600 l b - m o l / h r of i n s t r u m e n t a i r i s
s u p p l i e d t o t h e complex f r o m t h i s u n i t . (See Unit 1 2 7 . )

3.5.2 B o i l e r U n i t 122

P u r p o s e of t h e U n i t i s t o g e n e r a t e h i g h p r e s s u r e (HP)
steam f o r t h e b a l a n c e o f t h e power r e q u i r e m e n t s n o t
p r o v i d e d b y t h e v a r i o u s MP a n d Lp steam g e n e r a t o r s u s i n g
p r o c e s s waste h e a t .

-75-
 Description

The b o i l e r i s a c o a l f i r e d b o i l e r c o m p l e t e w i t h a l l
n e c e s s a r y e q u i p m e n t r e q u i r e d to p r o d u c e 1 6 0 9 p s i g
steam, i n c l u d i n g p r o v i s i o n s t o b u r n t h e s u p p l e m e n t a l
f u e l s and i n c i n e r a t e t h e s o u r o f f g a s e s l i s t e d below.
E f f i c i e n c y assumed i s 835%.

_Main
- - -F-u e l
Fine c o a l (composition l i s t e d i n Sub-section 2 . 3 )
Quantity 274.0 Mlb/hr
Low
_- h e a t i n g : v a l u e , as r e c e i v e d 7 , 8 9 3 BTU/lb
(See-Unit 128 p r o c e s s d e s c r i p t i o n . )

- m e-n t a l-F-
S u Q p-l e- u e-l s

- O i l ( f r o m G a s L i q u o r S e p a r a t i o n U n i t 107)
Quantity 35.90 Mlb/hr
Low h e a t i n g v a l u e 16,700 BTU/hr
- T a r (from G a s Liquor S e p a r a t i o n Unit 107)
Quantity 42.85 Mlb/hr
Low h e a t i n g v a l u e 15,700 BTU/lb
- P h e n o l s (from P h e n o l R e c o v e r y U n i t 1 0 8 )
Quantity 15.26 Mlb/hr
Low h e a t i n g v a l u e 7,800 RTU/lb

I n-
- c i-
n e-
r a-
tio
-n-F- u e-
l

- Sour o f f g a s e s ( m a i n l y from S u l p h u r Recovery U n i t 1 0 6 )

Quantity 1 , 5 9 2 . 4 Mlb/hr
Low h e a t i n g v a l u e 274 BTU/lb

Note: The h e a t c o n t e n t o f t h e s e g a s e s ( 3 0 BTU/SCF) h a s

n o t been i n c l u d e d i n t h e b o i l e r t h e r m a l balance.

Normal C a p a c i t y 2 , 2 9 1 . 2 Mlb/hr
Design Capacity 120% of n o r m a l

3.5.3 Main S u p e r h e a t e r U n i t 1 2 3
P u r p o s e o f t h e U n i t i s t o s u p e r h e a t t h e HP steam
g e n e r a t e d i n t h e b o i l e r f o r more e c o n o m i c u s e i n t h e
v a r i o u s H P steam t u r b i n e s .

Description

The main s u p e r h e a t e r c o n s i s t s o f a l l e q u i p m e n t c e c e s s a r y
t o p r o d u c e HP steam a t o u t l e t c o n d i t i o n s o f 9860F a n d
1,566 psig. I t is an i n t e g r a l p a r t of t h e b o i l e r system.
Unit 122 i n c l u d e s t h e f u e l r e q u i r e m e n t s f o r t h e s u p e r h e a t e r .
A 4 3 . 2 M l b / h r s l i p stream of b o i l e r steam i s n o t s u p e r -
heated.

-76-
3.5.4 Superheater Unit 124
Purpose of the Unit is to superheat surplus medium
and low steam produced in the process units.
DescriDt ion
The superheater consists of all equipment necessary
to superheat hlP and Lp steam as follows:
M P Steam LP Steam
Inlet Pressure, psig 571 100
Outlet Pressure, psig 550 55

Inlet Temperature, O F 4 u- 3 -33

Outlet Temperature, 04 748 502

In addition, each coil is controlled individually and is

able to be inactive while the other is fully operating.

The superheater is designed to burn part of the oil

recovered in the Gas Liquor Separation Unit 1 0 7 .
Efficiency assumed is 79%. w
Quantity of oil 1 5 . 8 1 Mlb/hr
Low heating value 1 6 , 7 0 0 BTU/lb

Normal CaDacitv
Coil 1: AlP steam supe-rhea/ting 7 6 5 . 5 Mlb/hr
Coil 2 : LP steam superheating 8 4 2 . 7 Mlb/hr

Design Capacity 105% of normal

3.5.5 Electrostatic Stack Gas Precipitator Unit 125

Purpose of the Unit is the removal of particulate matter
t o meet the state and federal environmental requirements
for coal fired boilers. (See Sub-section 2 . 6 )
Description
The unit consists of all equipment required to remove
the dust from Boiler Unit 122 stack gas to a level
which is compatible with the downstream Stack Gas Clean Up
Unit 126. The stack gas leaving Unit 126 will contain
0 . 1 pound of particulates per million BTU of fuel fired.

Normal Capacity 1 6 7 . 8 Mlb-mol/hr

Design Capacity 120% of normal

-77-
3.5.6 Stack Gas Clean-up Unit 126
Purpose of the Unit is to remove SO2 from the stack
gas to meet the state and federal regulations f o r coal
fired boilers. (See Sub-Section 2.6)
Description
The unit consists of all equipment required to remove
SO2 from the stack gas of Boiler Unit 122 to a level
of 0-.2 pounds SO2 per million BTU of fuel fired. The
SO2 absorbant is a lime slurry. The clean stack gas
is discharged to the atmosphere via a 300 foot stack.
Normal CaDacitv 1 6 7 . 6 Mlb-mol/hr, containing
3 6 . 1 lb-mol/hr SO2

Design Capacity 120% of normal

3.5.7 Instrument and Plant Air Unit 127 (not shown)
Purpose of the Unit is to supply instrument air for
A i r Separation Unit 1 2 1 and the boiler area only, and
to s u p p l y plant air for maintenance purposes. ( * I

DescriDt ion

The unit consists of all equipment, such as compressors

and dryers,to produce instrument and plant air. The
instrument air is available at 85 psig and -lO°F dew point.
The plant air will be available at a pressure ranging
from 85 to 140 psig.
Design Capacity
Plant air 100 lb-mol/hr
Instrument air 5 0 lb-mol/hr

(*) Instrument air f o r the total complex (estimated to

be 600 lb-mol/hr, normal) is supplied by the Air
Separation Unit 121, from a point where the air
is pressured and dried.

-78-
3.5.8 C o a l H a n d l i n e : U n i t 125

P u r p o s e o f t h e U n i t i s t o p r e p a r e t h e as mined c o a l
i n t o s u i t a b l e feedstocks f o r t h e g a s i f i e r s and boiler
and t o p r o v i d e coal storage.

T e c h n o l o g y Used

Commercial-type c o a l c r u s h i n g and s c r e e n i n g f a c i l i t i e s
are u s e d t o produce w e l l - s i z e d coal f o r g a s i f i c a t i o n
and f i n e s for boiler f i r i n g .

T h e w e l l - s i z e d c o a l i s i n t h e r a n g e of 1/4" t o 2 " ,
c o n t a i n i n g a p p r o x i m a t e l y 15% o v e r s i z e a n d 7% u n d e r s i z e .

Process D e s c r i p t i o n (SFD ZO-GEM-6909)

The coal i s d e l i v e r e d b y t r u c k s f r o m t h e a d j a c e n t m i n e
a r e a . They o p e r a t e s i x d a y s p e r week d e l i v e r i n g
a p p r o x i m a t e l y 32,000 t o n s per day. T r u c k s f l o o d u n l o a d
i n t o t h e t r u c k dump s t a t i o n h a v i n g f o u r dump p o c k e t s ,
each w i t h a f e e d e r o u t l e t d e s i g n e d t o accommodate two
t r u c k s s i m u l t a n e o u s l y . The c o a l d r o p s i n t o a b i n a n d i s
f e d i n t o t h e f o u r p r i m a r y c r u s h e r s by f o u r p l a t e f e e d e r s .

C r u s h e r s r e d u c e t h e s i z e t o m i n u s 8" w i t h a minimum
g e n e r a t i o n of f i n e s . The p r o d u c t of t h e p r i m a r y c r u s h e r s
d i s c h a r g e s o n t o two b e l t c o n v e y o r s f o r w e i g h i n g a n d
conveying t o t h e primary s c r e e n i n g s t a t i o n u s i n g
8" x 20" s i n g l e d e c k s c r e e n s . The m i n u s 2 " p r o d u c t i s
f e d t o t w o b e l t c o n v e y o r s a n d t h e p l u s 2" p r o d u c t i s
discharged i n t o secondary c r u s h e r s , which r e d u c e t h e
oversize c o a l t o m i n u s 2 " .

T h e m i n u s 2" c o a l i s t h e n c o n v e y e d t o a t r a n s f e r s t a t i o n
from w h e r e t h e c o a l i s d i r e c t e d t o t h e l i v e o r d e a d
storage p i l e s o r , through a by-pass conveyor, d i r e c t l y
t o secondary s c r e e n i n g . Normally, t h e conveyor t o t h e
l i v e s t o r a g e w i l l b e u s e d . The l i v e s t o r a g e area i s
s u f f i c i e n t f o r a b o u t s i x f u l l d a y s of p l a n t p r o d u c t i o n .
The d e a d s t o r a g e a r e a i s s u f f i c i e n t t o feed t h e p l a n t
f o r a p p r o x i m a t e l y 30 d a y s .
C o a l i s reclaimed f r o m l i v e - s t o r a g e v i a c o n v e y o r s a n d
is t r a n s f e r r e d t o t h e s e c o n d a r y s c r e e n i n g b u i l d i n g f o r
f i n a l s i z i n g i n t o g a s i f i e r a n d b o i l e r feeds. In t h i s
b u i l d i n g , t h e coal is f e d t o t h e s c r e e n s t h r o u g h v a r i a b l e
r a t e v i b r a t i n g f e e d e r s . The o v e r s i z e f r o m each s c r e e n
falls o n t o t w o c o l l e c t i n g conveyors f o r sampling and
t r a n s f e r t o t h e g a s i f i e r b u i l d i n g f e e d c o n v e y o r s . The
u n d e r s i z e p r o d u c t ( m i n u s 1/4") a l s o f a l l s o n t o t w o
collecting belts f o r transfer t o the f i n e s silo.

-79-
 Two belt conveyors, equipped with scales and samplers,
carry the fines from the storage silo to Boiler 122.
Normal Capacity
Gasifier feed (1/4" to 2") 1,901.3 hllb/hr
Fine Coal (minus 1/4") 3 7 6 . 5 Mlb/hr

3.5.9 Ash Handling Unit 129

\
Purpose of the Unit is to receive hot ash from the
gasifier ash l o c k s and cool the ash to a suitable
temperature for continuous transport and disposal
without formation of dust.

Technology Used
The ash handling system is a hydraulic sluiceway system
similar to the ash system used commercially by Sasol.
It has proven to be very satisfactory for handling the
ash from a large number of gasifiers.
Process Description (SFD ZO-GEM-6911)
The ash from the gasifiers discharges into totally
enclosed sluiceways located below grade under the gasifiers.
The ash from the gasifiers is quenched by a large circula-
ting stream of water which is recycled from the thickener
clear overflow. Exhaust Fan 129-C-01 exhausts a mixture
of air and water (steam) from the sluiceway. The stream
of air and water is quenched with water sprays before being
released to the atmosphere to reduce the water content of
the stream and to eliminate any dust.
The mixture of ash and water flows by gravity to Duplex
Spiral Classifier 129-Y-01 which separates the bulk of
the ash from the water. Fine ash and water from the
classifier flow by gravity into Classifier Sump 129-F-01
while solids from the classifier are fed to Conveyor 129-Y-02.
The water and fines from the classifier sump are pumped
to Thickener 129-F-02 which is a cone bottom center feed
rake thickener. The clear overflow from the thickener
flows to Thickener Overflow Sump 129-F-03. From this sump,
water is pumped back to the sluiceway by Thickener Overflow
Sump Pump 129-G-02. The bottoms of the thickener is
pumped by 129-G-01 to Filter 129-F-04. Filtrate is
recycled to the thickener by 129-G-04. Solids are fed to
the conveyor. The conveyor discharges the solids from
the filter and from the classifier into Ash Storage Bin
129-F-05.

-80-
 3.5.10 BFW P r e p a r a t i o n U n i t 131

-
-D -e a_e r_a t_o r_ (131L1)
_
/.3 P u r p o s e of S e c t i o n 131/1 i s t o d e a e r a t e t h e b o i l e r
f e e d water (BFW) b e f o r e steam g e n e r a t i o n .

Description

The d e a e r a t o r s e c t i o n u s e s c o m m e r c i a l - t y p e d e a e r a t i o n
e q u i p m e n t t o remove d i s s o l v e d g a s e s f r o m steam c o n d e n s a t e
and f r e s h water.

T h e d i s s o l v e d g a s e s i n t h e s e streams a r e removed by h e a t
s u p p l i e d f r o m Heat E x c h a n g e r 150-E-06. ( S e e PFD
ZO-GEM-69 15. )

A f t e r d e a e r a t i o n , t h e BFW i s pumped t o t h e v a r i o u s steam

g e n e r a t o r s . S t r i p p e d d i s s o l v e d gases are v e n t e d t o
t h e atmosphere.

Normal Capacity

Temp., Flow,
OF Mlb/hr

MP c o n d e n s a t e 483 86.5
LP c o n d e n s a t e 284 972.3
Vacuum c o n d e n s a t e 207* 2,461.3
Methanat i o n U n i t 112
process condensate 288

*
103.0
BFW make-up water 207*
- 2 066.9
Total 221

* After heating in 150-E-06

Design Capacity 120% of n o r m a l c a p a c i t y

Operating Pressure 17.6 p s i a

-D-e m- i_n e_r a_l i_z e_r _(.131/2)

__
P u r p o s e of S e c t i o n 131/2 i s t o p r o v i d e t h e h i g h q u a l i t y
water r e q u i r e d f o r h i g h p r e s s u r e steam g e n e r a t i o n .

-81-
 Description

Commercial-type equipment i s u s e d . The f r e s h water

is f i l t e r e d , s o f t e n e d and demineralized before flowing
t o Deaerator 131/1. ( T h e assumed f r e s h water a n a l y s i s
is r e p o r t e d i n Sub-section 2.3).

Normal C a p a c i t y 2 , 0 6 6 . 9 Mlb/hr

Design Capacity 120% o f n o r m a l

O p e r a t i n g Temperature 68OF ( * )

(*) The d i f f e r e n c e o f 20°F i n t h e f r e s h water t e m p e r a t u r e

l i s t e d i n S u b - s e c t i o n 2 . 3 r e s u l t s f r o m t h e u s e of
t h i s f r e s h water stream f o r d i r e c t c o o l i n g o f a i r
i n t h e Oxygen P r o d u c t i o n U n i t 1 2 1 .
3.5.11 C o o l i n g Water Make-up P r e p a r a t i o n U n i t 1 3 2

P u r p o s e of t h e U n i t i s t o t r e a t t h e f r e s h water r e q u i r e d
t o r e p l a c e l o s s e s i n t h e c o o l i n g water s y s t e m .
D e s c r i D tion

The f r e s h water i s s o f t e n e d a n d c h e m i c a l l y t r e z t e d t c
become s u i t a b l e f o r make-up t o t h e c o o l i n g t o w e r s y s t e m .
Commercial-type equipment is used. In addition t o
t r e a t e d f r e s h water, t h e b i o l o g i c a l l y t r e a t e d water
from Waste Water T r e a t m e n t U n i t 135 a n d t h e h u m i d i t y
of t h e a i r c o n d e n s e d i n A i r S e p a r a t i o n U n i t 1 2 1 a r e a l s o
u s e d a s c o o l i n g t o w e r make-up.

The CW make-up r e q u i r e m e n t h a s been e s t i m a t e d a s f o l l o w s :

P e r c e n t o f CW
Circulation

E v a p o r a t i o n losses 2.60
Drift 0.07
Blow-down ( * ) 0.33
Total 3.00
(*) Blow-down i s b a s e d on a h a r d n e s s of t h e s o f t e n e d
water o f 35 ppm C a C 0 3 .

-82-
 Normal CaDacitv
Mlb/hr

T r e a t e d f r e s h water 2,090.5
T r e a t e d w a t e r f r o m U n i t 135 a n d
humidity from Unit 1 2 1 1,994.9
Total 4,085.4

Design Capacity

Softening 200% o f f r e s h water

Chemicals 115% o f t o t a l w a t e r

3.5.12 C o o l i n g Water Tower U n i t 133

P u r p o s e of t h e U n i t i s t o s u p p l y t h e c o o l i n g w a t e r
n e c e s s a r y f o r t h e steam t u r b i n e c o n d e n s e r s a n d f o r t h e
p r o c e s s / o f f s i t e u n i t t r i m coolers.

Description

S t a n d a r d c o m m e r c i a l - t y p e c o o l i n g towers a n d pumps a r e
used t o p r o v i d e 75OF c o o l i n g water. The c o o l i n g
towers a r e d e s i g n e d f o r a maximum w e t b u l b t e m p e r a t u r e
o f 66OF. Make-up w a t e r i s s u p p l i e d t o t h e c o o l i n g
towers f r o m C o o l i n g Water Make-up P r e p a r a t i o n U n i t 1 3 2 .
Normal Capacity ( * >

Steam t u r b i n e c o n d e n s e r d u t y 191, 400

( t e m p e r a t u r e r i s e 75 t o 100°F a n d
d i s c h a r g e p r e s s u r e 50 p s i g )
Trim c o o l e r d u t y 81,725
(temperature r i s e 75 to 97OF avg.
a n d d i s c h a r g e p r e s s u r e 64 p s i g )
Total 273,125

Design Capacity 115% o f n o r m a l

(*) The CW c a p a c i t y i s based o n a i r c o o l i n g t o 130°F

a n d t r i m c o o l i n g b e l o w 130°F.

-83-
3.5.13 E l e c t r i c Power G e n e r a t i o n U n i t 1 3 4
P u r p o s e of t h e U n i t i s t o generate t h e e l e c t r i c power
r e q u i r e m e n t s for t h e p l a n t complex.

Description

E l e c t r i c power i s g e n e r a t e d f r o m c o m m e r c i a l - t y p e power
g e n e r a t o r s d r i v e n by steam t u r b i n e s u s i n g waste steam
from t h e p r o c e s s u n i t s . Two l e v e l s of steam a r e u s e d
t o g e n e r a t e e l e c t r i c p o w e r . G e n e r a t o r 134-M-01 u s e s
4 8 p s i g , 378OF steam w i t h C o n d e n s i n g T u r b i n e 134-"-01.
G e n e r a t o r 134-11-02 u s e s s u p e r h e a t e d 85 p s i g steam w i t h
Back P r e s s u r e T u r b i n e 134-T-02 e x h a u s t i n g t o 50 p s i g .

E l e c t r i c power i s g e n e r a t e d a t 6 , 0 0 0 V o l t s ; s t e p d o w n
t r a n s f o r m e r s are provided.

N o r m a l Capacity

Steam Flow,
MW Mlb/hr
134 -M- 0 1 43.5 883.4
134-M-02 7.9 842.7

Design CaDacitv 110% o f n o r m a l

3.5.14 Waste Water T r e a t m e n t U n i t 135

P u r p o s e of t h e U n i t i s t o t r e a t t h e waste a n d a c i d
w a t e r s of t h e t o t a l complex so t h a t t h e y c a n b e u s e d
a s p a r t of t h e c o o l i n g water make-up r e q u i r e m e n t s .

Description

The waste w a t e r t r e a t m e n t u n i t is a c o m m e r c i a l - t y p e ,
biological treatment process using air. I n addition,
t h e a c i d w a t e r w i l l be n e u t r a l i z e d using c a u s t i c soda.

Normal C a p a c i t y
Flow,
Composition Mlb/hr
Organic a c i d s and phenols 4.8
A c e t o n e p l u s c 6 + c o n t a i n i n g some H2S 2.2
Ammonia 1.3
Water 1,974.8
Total 1,983.1

Design Capacity

110% o f n o r m a l c a p a c i t y r e g a r d i n g t o water f l o w r a t e
130% of n o r m a l c a p a c i t y r e g a r d i n g t o c o m p o n e n t s .
-84-
3.5.15 Flare and Blow-Down Facilities 136 (not shown)
Purpose of the Unit is to provide relief for all
liquid and gaseous effluents from the complex.
Description
A commercial-type flare system burns all gaseous
streams coming from either process vents or safety
valves. The blow-down facility consists of a holding
pond to collect the cooling tower and steam system
blow-down streams.
Normal Capacity
Blow down water to holding pond 5 0 8 . 8 Mlb/hr

Design Capacity 130% of normal

3.5.16 Storage 137 (not shown)

The following is a summary of the intermediate, product
and chemical storage tank capacities which are not
located within the process and offsite units:
Product Storage (15 days)
Anhydrous ammonia 1,700 ton (refrigerated)
Sulphur 1,000 ton (covered)
Gasoline 364,000 Bbl (floating roof)
Propane LPG 26,000 Bbl (pressure)
Mixed butane 37,000 Bbl (pressure)
Intermediate Storage (15 days)
Methanol 870,000 Bbl (floating roof)
Raw gasifier n a p h t h a 22,000 B b l (floating r o o f )

Chemical Storage
Diisopropyl ether 1,500 Bbl

Coal Fines (7 days) 8,700 T (silo)

-85-
3.5.17 I n t e r c o n n e c t i n g Pipeway 138 ( n o t shown)

P u r p o s e of t h e U n i t i s t o p r o v i d e p i p i n g a n d racks f o r
connection between t h e v a r i o u s p r o c e s s u n i t s and
between t h e p r o c e s s and o f f s i t e u n i t s .

3.5.18 R e f r i g e r a t i o n U n i t 141

P u r p o s e of t h e U n i t i s t o s u p p l y t h e r e f r i g e r a t i o n
r e q u i r e m e n t s f o r t h e p l a n t complex.

Descr i p t i o n
An ammonia a b s o r p t i o n r e f r i g e r a t i o n s y s t e m i s u s e d .
T h i s p r o c e s s u s e s t h e 20 p s i g waste steam w h i c h c a n n o t
be u t i l i z e d i n a n o t h e r w a y . Two t e m p e r a t u r e l e v e l s of
r e f r i g e r a t i o n are p r o v i d e d .

Normal Capacity

---Duty, MMBtu/hr---

Temperature Level +32'F -45'F

P u r i f i c a t i o n U n i t 105 and
ammonia s t o r a g e 25.5 70.5

Design C a p a c i t y 110% of n o r m a l

3.5.10 G a s o l i n e B l e n d i n g U n i t 154

P u r p o s e of t h e U n i t i s t o b l e n d i n - l i n e t h e v a r i o u s
c o m p o n e n t s c o n t i n u o u s l y a n d a u t o m a t i c a l l y i n t o a 10 RVP
gasoline product.

Description

A t y p i c a l commercial i n - l i n e b l e n d i n g o p e r a t i o n i s c a r r i e d -
o u t as f o l l o w s :

- Component samples are t e s t b l e n d e d i n t h e l a b o r a t o r y

t o determine t h e proper blending and a d d i t i v e r e c i p e .
- Blending r e c i p e r e q u i r e m e n t s are e n t e r e d i n t o t h e
blending control system.
- A f t e r i n i t i a l checking, o p e r a t i o n is p l a c e d on-stream
and t h e g a s o l i n e product is s e n t t o f i n a l s t o r a g e .

Equipment c o n s i s t s of rundown t a n k s , t h e b l e n d i n g c o n t r o l
system w i t h v a l v e s , flow m e t e r s , a n a l y z e r and c o n t r o l l e r s ,
a n d pumps.

-86-
 Q
1-
MINE0 COAL

TRUCK DUMP &

277824

PRIMARY CRUSHING
CASE I

CASE I 1

. PRIMARY SCREENING1 &

SECONDARY CRUSHING

5
TRANSFER STAT ION

BY - PASS

SECONDARY
l-t
-'4
'
LIVE STORAGE PILE

----- J
I
I

SCREENING

Ll
CASE I AND 11

c;
WELL SIZE0 COAL
NOTES
STREAMS WITHOUT STREAM NUMBERS

I
ARE NOT INCLUDED I N THE OVERALL

DlST RlBUT ION TOWER MATERIAL BALANCE

THIS SFO I S IDENTICAL FOR B A S E CASE I AND I1

IN GASIFICATION EXCEPT AS NOTED

UNIT 101 BUILDING

? .WO CASE 1

t- 40LSW CASE I1

FINE COAL FINE COAL

TO BOILER TO SALES
UNIT 122 -87-
I I
1 J
II
 SLUn w S U Ew ? RE-
FROM TO@ IC SLUICE VENT
TO ATMOSPHERE

P
UNll UNll 11
L

w 129-C-01

t ASH & S L U I C E W A T E R
FROM GASIFICATION
GASIFIER ASH SLUICES UNIT 101

AIR

4 + 0
19-6-01
19-G-02 BOTTOMS PUMP
THICKENER OVERFI.OI SUMP PUMP 2 + 2
LB-G-03 CLASSIFIER SUMP PUMP 2 + 2
19-c-04 FILTRATE PUMP 4 + 0

19-Y-01 DUPLCX SPIRAL. CLASSIFIER 4 + 0

'9-Y-02 CONVEYOR 2 1 2

129-G-03
129-F-0 1

129-F-0:
r

12 9- G-02

"I 129-G-01

N
STREAMS
OTES. WITHOUT STREAM NUM9ERS

ARE NOT INCLUDED IN THE OVERALL

MATERIAL BALANCE

I 129-F-04 THIS SFO IS IDENTICAL FOR BASE CASE I AND 11

129-F-05

v
ASH
TO TRUCK LOAD OUT
v

ICFF SITE UNIT1

-88- UNIT 1 2 9 / 2 2 9 EASE CASE 01
 BASE CASE I
3.6 UTILITY REQUIREMENTS A N 2 STEAhl/BFW BALANCE

\ 3.6.1 U t i l i t y Requirements

U t i l i t y r e q u i r e m e n t s f o r t h e i n d i v i d u a l u n i t s can b e
found as f o l l o w s :

Utility Source

Fue 1 Type and s t r e a m number: BFD ZO-GEM-6894

(Sub-sect ion 3 . 4 )
Q u a n t i t y and composition: M a t e r i a l
b a l a n c e s h e e t s (Appendix A )
Power BFD ZO-GEM-6894
Cooling water BFD ZO-GEM-6894
Boiler feed water Steam/BFW Balance ZO-GEM-6910
(Sub-sect ion 3 . 6 )
Steam St eam/BFW Balance ZO-GEM-69 10

I n a d d i t i o n , o f f s i t e Sub-section 3 . 5 c o n t a i n s u t i l i t y
information.

3.6.2 Steam/BFW Balance

The steam a n d b o i l e r f e e d water flows a r e shown on

Drawing ZO-GEM-6910. T h e s t e a r n / e l . e c t r i c power b a l a n c e
i s a c c e p t a b l e i n accordance w i t h t h e s t u d y b a s e s . O n l y
about 6 MW(e) i s s u r p l u s i n comparison w i t h 249 MW of t o t a l
e l e c t r i c and steam power r e q u i r e d i n t h e p l a n t complex.
I n a d d i t i o n , e x c e p t for about 43 Mrlb/hr of 20 p s i g
s t e a m , a l l steam produced i s u t i l i z e d .

-89-
 * UNIT 103 g-

1 UNIT 1OL 8-

UNIT 108 -
r

I UNIT 102 *.

I UNIT 1 0 3 _1-

UNIT 113

UNIT 153

UNIT 105 *-
r - UNIT 101 *-
UNIT 108
UNIT 1 0 L
UNIT 1 0 9
UNIT 150

-I
0

I
\D
_-
- 0-
I

-
1

13L-T-02
E l Power

? 131-M-02

4
t
*

eYe-YLi e N errr +.e e r w +. N N ID ID ID e r r N r u-w..w _I

* + + + + + + + + + + + + + 1 + + + + + + t + + + + * + +++++ + ,8
0 0 0000 00 0 00 0 0 0 0 0 0 0 0 0 0 0 w w e w r e
!E
0 0 0 0 0 0
 BASE CASE I
3.7 TRAIN PHILOSOPHY

he train philosophy for the various units was selected on the

asis of providing a plant complex having an onstream factor of
92%. Consequently, parallel trains have been used for many units
to give flexibility in both operation and maintenance. Also,
because of the large size of the complex, some m i t s must be
divided into parallel trains. In the methanol conversion and
hydrocarbon processing area, however, intermediate storage Is
used to provide this flexibility.
In addition, all normally operating pumps, reciprocating compressors
and conveyors are provided with an 100% spare.
The following is a summary of the train philosophy used for each
unit:
Gasification Unit 101
Two parallel trains, each containing 14 Lurgi gasifiers, are used.
Each gasifier includes a wash cooler, waste heat boiler and other
associated equipment.

Only 25 gasifiers will be required t o produce the design snythesis

gas quantity. The other three spare gasifiers can be withdrawn
from service for maintenance.
Raw Gas Shift Unit 102
Two parallel trains are provided because of reactor size limitations
and to provide operating flexibility.
Raw Gas Cooling Unit 103
Three parallel trains are provided due to the size limitation of
the heat exchangers.
Shifted Gas Cooling Unit 104
One train is provided since the heat exchange equipment is small
and a centrifugal booster compressor is provided.
Gas Purification Unit 105
The absorber and regenerator section is divided into four parallel
trains to allow towers to be shop fabricated. All the other
sections of the unit are divided into two parallel trains for
operating flexibility.

-91-
 S u l p h u r R e c o v e r y U n i t 106

The a b s o r b e r s e c t i o n i s d i v i d e d i n t o f o u r p a r a l l e l t r a i n s d u e t o
t h e l a r g e size of t h e a b s o r b e r s . In a d d i t i o n , because of t h e
h e i g h t r e q u i r e m e n t s of t h e a b s o r b e r s , each t r a i n w i l l c o n t a i n two
a b s o r b e r s i n s e r i e s . A l l o t h e r s e c t i o n s of t h i s u n i t a r e d i v i d e d
i n t o two p a r a l l e l t r a i n s f o r o p e r a t i n g f l e x i b i l i t y .

G a s L i q u o r S e p a r a t i o n U n i t 107

The d u s t y g a s l i q u o r s e p a r a t i o n e q u i p m e n t i s d i v i d e d i n t o t h r e e
t r a i n s t o p r o v i d e o p e r a t i n g f l e x i b i l i t y and t o keep t h e equipment
reasonably sized.

P h e n o l R e c o v e r y U n i t 108

The p h e n o l e x t r a c t i o n s e c t i o n i s d i v i d e d i n t o two p a r a l l e l t r a i n s
f o r o p e r a t i n g f l e x i b i l i t y and f o r reasonably s i z e d equipment.

Ammonia R e c o v e r y U n i t 109

The t o t a l s t r i p p e r a n d a s s o c i a t e d e q u i p m e n t i s d i v i d e d i n t o t w o
p a r a l l e l t r a i n s because of size l i m i t a t i o n s .

M e t h a n o l S y n t h e s i s U n i t 110

Because of manufacturing s i z e l i m i t a t i o n s , t h i s u n i t is d i v i d e d
into four parallel reactor trains. A l s o , two f e e d / r e c y c l e c e n t r i f u g a l
compressors are provided f o r o p e r a t i n g f l e x i b i l i t y .

H 2 R e c o v e r y U n i t 111

One t r a i n i s p r o v i d e d .

Methanation Unit 112

Two p a r a l l e l reactor t r a i n s a r e p r o v i d e d f o r o p e r a t i n g f l e x i b i l i t y .
C 0 2 Removal U n i t 113

One t r a i n i s p r o v i d e d .

SNG D r y i n g U n i t 114

One t r a i n i s p r o v i d e d .

-92-
M e t h a n o l C o n v e r s i o n U n i t 150
Naphtha H y d r o t r e a t i n g U n i t 151
a c t i o n a t i o n Unit 152
k y l a t i o n U n i t 153

A l l a r e s i n g l e t r a i n u n i t s . They a r e d e c o u p l e d from t h e g a s i f i c a t i o n
a n d m e t h a n o l s y n t h e s i s s e c t i o n s by 15 d a y s of t a n k c a p a c i t y f o r t h e
crude methanol and r a w naphtha. I n a d d i t i o n , U n i t 150 h a s t h e
f o l l o w i n g reactor c o n f i g u r a t i o n s f o r e f f i c i e n t o p e r a b i l i t y :

Reactors Design

F i r s t - s t a g e DME 2 i n parallel for possible 3 to 6

month r e g e n e r a t i o n
S e c o n d - s t a g e hl-Gasol i n e 6 i n p a r a l l e l f o r 14 day c y c l i c
regenerat ion

Offsite Units

The o f f s i t e u n i t s a r e d e s i g n e d f o r a minimum of t w o p a r a l l e l t r a i n s .
I n cases w h e r e c o m m e r c i a l - s i z e d e q u i p m e n t i s t o o l a r g e w i t h t w o
t r a i n s , t h e number of t r a i n s h a s b e e n i n c r e a s e d .

-93-
 SECTION 4

BASE CASE I1

FISCHER-TROPSCH TECHNOLOGY

4.1 MATERIAL BALANCE

The o v e r a l l m a t e r i a l b a l a n c e i s shown b e l o w :

Input Mlb/hr

C o a l , a s mined 2 , 3 0 8 . 2 (1)
Air 6,320.8
Water 4,374.9
Other 7.9
13,511.8

output Mlb/hr

Ash 147.4
Products, ,ncluding a l c o h o l s 519.7(2)
Byproducts 13.7
Blowdomn w a t e r 526.6
S t a c k and v e n t l o s s e s 12,298.5
Other 5.9
13,511.8

2 7 , 6 9 8 T/SD
(2) 4 8 , 7 6 0 Bbl/SD

O v e r a l l p l a n t c o n s u m p t i o n s p e r Uarrel o f p r o d u c t , c o n v e r t i n g S N G
i n t o a FOE b a r r e l , a r e :
Coal : 0.568 T
Water: 6 . 1 5 Bbl
Air: 1.68 T

S t a c k a n d v e n t losses amount t o a b o u t 3 . 0 t o n s p e r b a r r e l of
product.

Appendix B c o n t a i n s t h e c o m p l e t e , d e t a i l e d m a t e r i a l b a l a n c e f o r
Base C a s e 11.

-94-
 BASE CASE I 1
4.2 PRODUCT YIELDS AND QUALITY

tream numbers are given below for reference to the material

alance sheets in Appendix B and process diagrams in Sub-section
4.4.

4.2.1 SNG (49)

Quantity 19,023.3 lb-mol/hr

315.4 Mlb/hr
173.3 MAISCF/SD

Composition (Only compounds greater than 0.1% are

listed; see Appendix B for detailed
composition.)
Percent
Hydrogen 3.8
Methane 89.7
Ethene 1.0
Ethane 2.3
Propene 1.0
Propane 0.1
Carbon dioxide 0.5
Inerts (Nz + A r ) 1.6
100.0

Other
Heat of combustion (HHV) 1,003 Btu/SCF
Carbon monoxide (0.1% max.) 0.07%
\Vater 0.01%
Sulfur None
Compatibility Indexes (versus pure methane)
Index Calculated Preferable Object ionab1e
Lifting, 11 0.99 under 1 . 0 above 1.06
Flash-back, If 1.06 under 1.15 above 1.2
Yellow-tip, 0.97 above 1 . 0 under 0 . 8
IY
The SNG product is of satisfactory quality and is interchangeable
with pure methane. The olefin nature of the Fischer-Tropsch light
gases, however, gives rise to a yellow-tip index value slightly
below the preferable value. If the olefins prove troublesome in
actual tests, an expensive hydrogenation step for olefin saturation
could be added.

-95-
4.2.2 Gasoline (50)
Quantity 13,580 Bbl/SD
140.9 Mlb/hr

Blending
Component Wt. %
Mixed butanes 2.7
Light hydrocarbons 2.9
Alkylate 2.7
Light polymer gasoline 16.3
Hydrogenated heavy polymer gasoline 14.3
C 5 / c 6 isomerate 25.1
Reformate 23.8
Hydrotreated gasifier naphtha 11.0
100.0

Properties
Estimated properties and a comparison with unleaded
gasoline specifications are presented in Table 4.2.1.
This gasoline meets all specifications. Compared to
typical present-day gasolines, it is slightly lower
in gravity and contains fewer aromatics.
Heavy polymer gasoline hydrogenation has been added in
order to meet the olefin target of 20 v o l . %
' max.
Without hydrogenation, the following are estimated:
(Research + Motor)/2 = 88.5
Olefin, vol. 70 = 28
Mobil and industry experience with high olefinic
gasolines is limited. Consequently, marketing such
a gasoline would require extensive testing and,
perhaps, additive package reformulation.

-96-
 TABLE 4.2.1

COiMPARISON OF PRINCIPAL UNLEADED GASOLINE SPECIFICATIONS

WITH ESTIMATED FISCHER-TROPSCH GASOLINE PROPERTIES -
CASE I1

Estimated F-T
Unleaded Gasoline
Properties Specifications

Gravity, OAPI 67.2

Octane Numbers
Research 91
Motor 83 82 min.
(Research + Motor)/2 87 87 min.

Volatility
Reid Vapor Pressure, lb 10.0
Distillation, OF
IBP 86.5
10% 108.9 158 max.
30% 137.3
50% 186.0 170/250 min./max.
70% 249.6
90% 335.2 374 max.
EP 420.6 437 max.

V/L Ratio (=20), OF Q127.3 @140 max.

Sulfur, wt. 70 Nil 0.10 max.

Composition, v o l . %
'
Paraffins 60.5
Olefins 19.9 20 max. (target)
Naphthenes 3.1
Aromatics 16.5

Mo 1ecu1ar We ig ht 93.1

-97-
4.2.3 Diesel Fuel (117)
Quantity 2,307 Bbl/SD n
25.4 b!lb/hr
Properties
Estimated properties and a comparison with diesel fuel
specifications are shown in Table 4.2.2.
This product could be marketed as a premium diesel oil,
Grade No. 1-D, for engine service requiring frequent
speed and load changes. Its relatively high estimated
cloud point, however, could preclude it being marketed
in cold weather regions.
4.2.4 Heavy Fuel Oil (118)
Quantity 622 Bbl/SD
7.4 Mlb/hr
Properties
Estimated properties and a comparison with gas turbine
fuel o i l specifications are shown in Table 4.2.3.
Because of the non-existant sulfur and metals contents,
this product could be marketed as a premium gas turbine
fuel .
4.2.5 Alcohols (156)
Quantity 2,025 B/SD
510 hllb/hr
Composition
Composition of the mixed alcohol product is:
Wt. %
Ethanol 59
I-propanol 14
N-propanol 14
2-but an01 4
I-butanol 1
N-but an01 5
2-pentanol 1
N-pentanol 1
c6 plus 1
100
The alcohol product is essentially free of acids, aldehydes,
ketones and water.
-98-
 TABLE 4.2.2
COMPARISON OF PRINCIPAL DIESEL FUEL SPECIFICATIONS WITH
ESTIMATED FISCHER-TROPSCH DIESEL FUEL PROPERTIES - CASE I1

DIESEL FUEL-ASTM D975(1)

Estimated F-T
Grade Grade Diesel Fuel
NO. 1-D NO. 2-D Other Properties
I_

Gravity, O A P I 56
Cetane Number, min. (D613 or D976)
Volatility
> 50
90% min. /max. OF (D86) -/550 540/640(5) 520
Q
I Flash Point *F min. (D93) 100 125 125
y Cloud Point, *F (D2500) (3) (3) 10-20
Viscosity, Kin. 8 100°F min./max.
(D445) 1.4/2.5 2.0p.3 2
Sulfur, wt. % max. (D129) 0.50 0.50 (4) None
Corrosion, max. (D130) No. 3 No. 3 No. 1
Carbon Residue on 10% Resid.,
max. (D524) 0.15 0.35 Trace

(1) 1976 Annual Book of ASTM Standards.

(2) V a r i o u s engine builders' requirements.
( 3 ) Varies with marketing region; maps included in ASTM D975.
(4) Varies in individual states, some as l o w as 0.3%.
(5) 540/6SO 90% min./max. proposed but currently not accepted by industry.
 TABLE 4.2.3
COMPARISON OF PRINCIPAL FUEL OIL AND GAS TURBINE FUEL OIL SPECIFICATIONS WITH
ESTIMATED FISCHER-TROPSCH HEAVY FUEL OIL PFNOPERTIES - CASE I1

Fuel Oil Gas Turbine F.D. Estimated F-T

No. 5 (Light) NO. 3 - GT Hvy. Fuel Oil
Fuel Oil ASTM D396* ASTM D2880* Properties
Gravity, O A P I - 41
Volatility
Flash Point, OF min. (D93) 130 or Legal 130 or Legal 150
I
Distillation - - -
P
8I Ash, wt. % max. ( 0 4 8 2 ) 0.10 0.03 Trace
Viscosity, SSU at 100°F, min. (D445) 150 45 Satisfactory
Sulfur, wt. % (D129) Legal - None
Metals, ppm (wt.) max.
Vanadium 2 0
Sodium + Potassium 5 Trace
Calcium 10 0
Lead 5 0

*1976 Annual Book of ASThl Standards.

4.2.6 Butane LPG ( 1 3 9 )

Quantity 146 Blb/SD

1 . 2 bllb/hr

Properties
Estimated properties and a comparison with LPG
specifications are shown in Table 4 . 2 . 4 .
This product is a satisfactory commercial butane
fuel .
4.2.7 Propane LPG ( 1 3 8 )

Estimated properties and a comparison with LPG

specifications are shown in Table 4 . 2 . 4 .
This product is a satisfactory commercial propane fuel.
4.2.8 Byproducts
Sulfur (29)
Quantity 61 T/SD
Impurities 0 . 5 wt. %

Anhydrous Ammonia (17)

Quantity 103 T/SD
Impurities (mainly water) 0.5 wt. %
' max.
Grade agricultural
Excess Power (6,000volts) 7 . 0 1 W(e)

-101-
 TABLE 4.2.4
COMPARISON OF PRINCIPAL LPG SPECIFICATIONS WITH
ESTIMATED FISCHER-TROPSCH LPG PROPERTIES - CASE I1

Comer c ia1 Est. F-T Comercia1 Est. F-T

Propane C3 LPG Butane C4 LPG
ASThl D1835* Properties ASTM D1835* Properties

Vapor Pressure at 100°F, max.,

psig (D1267) 208 178 70 37
I
w Volatile Residue
Butane and Heavier, max. vol. %
N
I (D2163) 2.5 1 - -
Pentane and Heavier, max. vol. %
(D2163) - - 2.0 1

Corrosion, max. (D1838) No. 1 No. 1 No. 1 No. 1

Sulfur, grains (D2784) 15 None 15 None

*1976 Annual Book of ASThl Standards.

 BASE CASE I 1
4.3 THERMAL EFFICIENCY

a b l e 4 . 3 . 1 i s a summary o f t h e o v e r a l l p l a n t t h e r m a l e f f i c i e n c y ,
q h i c h is d e f i n e d as t h e combustion h e a t o f t h e p r o d u c t s , byproducts
a n d excess power d i v i d e d by t h e c o m b u s t i o n h e a t of t h e t o t a l
coal f e e d . The e f f i c i e n c y h a s b e e n c a l c u l a t e d u s i n g b o t h t h e
h i g h and l o w h e a t i n g values.

-103-

-
 TABLE 4.3.1
FISCHER-TROPSCH CASE I1 - THERMAL EFFICIENCY
a
Quantity, High Heating rota1 HHV, Percent Low Heating rota1 LHV Percent
Unit/ SD Value (HHV) MMBtu/ h r of Input Value (LHV) UMBtu/h r o f Input

Input -
Coal, DAF ' 18,530 T 12,720Btu / lb 19,642 - 12,236Btu/lb 18,894")
Methanol I 4 T 9,79OBtu/lb 3 - 8,61OBtu/lb 3
19,645 18,897
output
SNG 173.26MMSCF 1,003.3Btu/SCF 7,243 36.9 904.7Btu/SCF 6,531 34.6
I C3 LPG 1,107Bbl 3.815MMBtu/Bbl 176 0.9 3.514MMBtu/Bbl 162 0.9
C4 LPG 146Bbl 4.321MMBtu/Bbl 26 0.1 3.991MMBtu/Bbl 24 0.1
4
I
10 RVP Gasoline 13,580Bbl 5.023MMBtu/Bbl 2,842 14.5 4.682MMBtu/Bbl 2,649 14.0
Diesel Fuel 2,307Bbl 5.345MhfBtu/Bbl 514 2.6 4.994MMBtu/Bbl 480 2.5
Hvy. Fuel Oil 622Bbl 5,682MMBtu/Bbl 147 0.7 5.326MMBtu/Bbl 138 0.7
Sub-Tota 1 10,949 55.7 9,984 52.8
Al coho 1s 510Mlb 13,63OBtu/lb 2 90 1.5 12,38OBtu/lb 263 1.4
Sulfur 61 T 3,78OBtu/lb 19 0.1 3,78OBtu/lb 19 0.1
Ammonia 103 T 9,693Btu/lb 83 0.4 8,02OBtu/lb 69 0.4
Power 6.0lMW( e) 3,415Btu/kWH 20(2) 0.1 3,415Btu/kWH 20(2) 0.1
Total 11,361 57.8 10,355 54.8

(1) If LHV of as mined coal used (7,893 Btu/lb), overall LHV thermal efficiency becomes 56.8%.
(2) Direct thermal conversion used.
 BASE CASE I1
4.4 PROCESS DESCRIPTIONS

he discussions below follow the block flow diagram (BFD) or the

rocess flow diagram (PFD) as noted. These diagrams are placed
at the end of the discussion. The gasification, raw gas treating
and byproduct recovery units, however, are identical to those in
Base Case I ; consequently, their PFD's are found in Sub-section 3 . 4
Detailed compositions and flows of the numbered streams are found
on the material balance sheets in Appendix B.

4.4.1 General (BFD ZO-GEM-69S8)

Sized coal is received from the offsite Coal Handling
Unit 228 (see Sub-section 4 . 5 ) , and is gasified in
Gasification Unit 2 0 1 . A portion of the raw gas
generated is converted in Raw Gas Shift Unit 202 to
meet the H2/CO ratio requirements of F-T Synthesis
Unit 2 5 0 . The raw gas and shifted gas are cooled in
Raw Gas Cooling Unit 203 and Shifted Gas Cooling
Unit 2 0 4 , respectively, before flowing to Gas Purifica-
tion Unit 205. This unit removes the H2S, CO2 and
naphtha from the raw gas. The H2S contained in the
purification unit offgas is converted to sulphur in
Sulphur Recovery Unit 2 0 6 . The purified gas (synthesis
gas) is sent to F-T Synthesis Unit 2 5 0 where it is
converted to hydrocarbon products.
The gas liquor condensed in Units 2 0 1 , 2 0 2 , 203, 2 0 4 ,
and 2 0 5 flows to Gas Liquor Separation Unit 207 in
which dusty tar and oil are recovered. The gas liquor
is further processed in Phenol Recovery Unit 2 0 8 and
Ammonia Recovery Unit 2 0 9 before flowing to Waste Water
Treatment Unit 2 3 5 .
The products from the F-T synthesis are upgraded and
recovered in the following units: F-T Product Fractiona-
tion Unit 252, F-T Product Hydrotreating Unit 253,
Hydrotreated Product Fractionation Unit 2 5 4 , Catalytic
Reforming Unit 255, C5/Cg Isomerization Unit 2 5 6 , Catalytic
Polymerization Unit 257, HF Alkylation Unit 2 5 8 , P o l y
Gasoline Hydrogenation Unit 259, Light Ends Recovery
Unit 260 and Alcohol Recovery Unit 2 6 2 . The final
products produced in these units are gasoline, diesel fuel
oil, heavy fuel oil, n-butane LPG, propane LPG and alcohols.

In addition to the liquid products, SNG is produced in

the SNG-upgrading train from the light gases produced in
F-T Synthesis Unit 2 5 0 . This train consists of Hydrocarbon
Recovery Unit 210, Methanation Unit 2 1 2 , where unreacted
CO, H2 and hydrocarbons are converted to methane, C02
Removal Unit 213, and SNG Drying and Compression Unit 2 1 4 .

-105-
 The h y d r o g e n r e q u i r e d f o r h y d r o t r e a t i n g t h e F-T s y n t h e s i s
p r o d u c t s and t h e naphtha from g a s i f i c a t i o n is produced
f r o m h y d r o g e n c o n t a i n i n g o f f g a s e s i n Hydrogen R e c o v e r y
U n i t 2 1 1 a n d Hydrogen P u r i f i c a t i o n U n i t 2 6 1 .

4.4.2 G a s i f i c a t i o n Area (BFD ZO-GEM-6988)

Because t h e s t u d y b a s i s c a l l s f o r t h e same s y n t h e s i s
gas production i n both base cases, t h e u n i t s i n t h e
c o a l g a s i f i c a t i o n area, i n c l u d i n g g a s t r e a t i n g and
product r e c o v e r y , are i d e n t i c a l .

Unit PFD ZO-GEM

201-Gasification 6 8 9 5 8i 6896
( I n B a s e Case I , Lock G a s C o m p r e s s o r 101-C-41 r e c o m p r e s s e s
t h e syngas compressor l o s s e s . I n Base Case 11, t h e s e
l o s s e s have been n e g l e c t e d . )

202-Raw G a s S h i f t 6897
203-Raw G a s C o o l i n g 6898
204-Shifted G a s Cooling 6899
205-Gas P u r i f i c a t i o n 6900
206-Sulfur Recovery 6901
207-Gas L i q u o r S e p a r a t i o n 6902
208-Phenol Recovery 6903
209-Ammonia R e c o v e r y 6904

C o n s e q u e n t l y , d e s c r i p t i o n s of t h e s e u n i t s a r e n o t r e p e a t e d
i n t h i s sub-section.

4.4.3 H y d r o c a r b o n R e c o v e r y U n i t 210 (PFD ZO-GEM-6973)

P u r p o s e of t h e U n i t i s t o remove a n d r e c o v e r h e a v y
h y d r o c a r b o n s from t h e F i s c h e r - T r o p s c h s y n t h e s i s p u r g e
gas t o meet m e t h a n a t i o n f e e d s t o c k s p e c i f i c a t i o n s .

T e c h n o l o g y Used

The c o m m e r c i a l p r o c e s s u s e d i s a low t e m p e r a t u r e h e p t a n e
wash. This p r o c e s s is conventionally used t o handle
a gas c o n t a i n i n g C02 b e c a u s e t h e o p e r a t i n g t e m p e r a t u r e
is h i g h enough t o p r e v e n t f r e e z i n g o f t h e C 0 2 .

-106-
 Process D e s c r i p t i o n

The f e e d g a s i s cooled a g a i n s t t h e p r o d u c t g a s a n d b y
r e f r i g e r a t i o n i n 210-E-01, 0 2 , a n d 03 t o c o n d e n s e t h e
b u l k of t h e h i g h e r h y d r o c a r b o n s b e f o r e b e i n g c h a r g e d
t o Wash Absorber 210-D-01. To p r e v e n t f r e e z i n g o f
w a t e r , a s m a l l a l c o h o l stream i s i n ' j e c t e d i n t o t h e
feedgas. I n t h e a b s o r b e r , t h e f e e d gas f l o w s c o u n t e r -
c u r r e n t l y t o t h e h e p t a n e s o l v e n t w h i c h i s pumped f r o m
H e p t a n e R e g e n e r a t o r 210-D-02 t h r o u g h Heat E x c h a n g e r
210-E-05 a n d C h i l l e r 210-E-04 t o t h e t o p of t h e a b s o r b e r .

The r i c h h e p t a n e l e a v i n g t h e absorber i s f e d t o t h e
h e p t a n e r e g e n e r a t o r i n which t h e absorbed hydrocarbons
a r e removed by f r a c t i o n a t i o n . The r e g e n e r a t o r o v e r h e a d
p r o d u c t v a p o r i s c o m p r e s s e d by 210-C-01, cooled a n d
combined w i t h t h e l i q u i d stream w h i c h i s c o n d e n s e d f r o m
t h e f e e d g a s i n f r o n t of t h e a b s o r b e r . The combined
stream i s s e n t t o F-T P r o d u c t F r a c t i o n a t i o n U n i t 2 5 2 .
The a b s o r b e r o v e r h e a d p r o d u c t gas f l o w s t o M e t h a n a t i o n
Unit 212.

I 4.4.4 H z R e c o v e r y U n i t 2 1 1 (PFD ZO-GEM-6974)

Purpose of t h e Unit is t o r e c o v e r hydrogen f o r u s e i n t h e

p l a n t hydrogenation/hydrotreating u n i t s . The f e e d s t o c k
is a s l i p s t r e a m o f t h e p r o d u c t g a s f r o m h y d r o c a r b o n
recovery.

I T e c h n o l o g y Used

B e c a u s e o f t h e r e l a t i v e l y h i g h CO2 c o n t e n t of t h e f e e d g a s ,
t h e P r e s s u r e Swing P r o c e s s o f Union C a r b i d e C o r p . i s u s e d .

Process D e s c r i p t i o n
The u n i t c o n s i s t s of f o u r p a r a l l e l p r e s s u r e - s w i n g a b s o r b e r s ,
211-D-01, w i t h o n e o n s t r e a m a n d t h e o t h e r t h r e e u n d e r g o i n g
r e g e n e r a t i o n . D u r i n g o p e r a t i o n , e s s e n t i a l l y a l l of t h e
non-hydrogen c o m p o n e n t s a n d a p o r t i o n o f t h e h y d r o g e n
are absorbed. The r e m a i n i n g h y d r o g e n l e a v e s t h e a b s o r b e r
a t a p u r i t y of o v e r 98%.
R e g e n e r a t i o n i s by p r e s s u r e r e d u c t i o n i n 3-stages w i t h
t h e f i n a l p r e s s u r e b e i n g n e a r l y a t m o s p h e r i c . The s y s t e m is
c o n t r o l l e d a u t o m a t i c a l l y by motor v a l u e s . An a b s o r p t i o n /
regeneration cycle r e q u i r e s several minutes.

The d e s o r b e d g a s e s , c a l l e d p r e s s u r e - s w i n g o f f g a s e s , a r e
r e c o m p r e s s e d by Compressor 211-C-01 a n d r e t u r n e d t o t h e
SNG u p g r a d i n g t r a i n as f e e d t o M e t h a n a t i o n U n i t 2 1 2 . Gas
H o l d e r 211-F-01, on t h e s u c t i o n s i d e o f t h e c o m p r e s s o r , i s
required f o r buffering t h e non-static, pressure-swing
-107-
 o f f g a s flow from t h e r e g e n e r a t i n g a b s o r b e r s .

For c l a r i t y p u r p o s e s , t h e h y d r o g e n - s o u r c e streams a n d
t h e h y d r o g e n - f e e d s t r e a m s a r e shown a s p a r t o f t h e
PFD f o r U n i t s 211 a n d 251. Hydrogen c o m p r e s s o r s
211-C-03 a n d 04 a r e a l s o i n c l u d e d .

4.4.5 M e t h a n a t i o n U n i t 212 (PFD-ZO-GEM-6975)

P u r p o s e o f t h e U n i t i s t h e p r o d u c t i o n o f SNG m e e t i n g t h e
specifications f o r i n t e r c h a n g e a b i l i t y with e x i s t i n g
p i p e l i n e gases. I n a d d i t i o n , t h e CO c o n t e n t must b e
l o w e r e d t o l e s s t h a n 0.1%.

T e c h n o l o g y Used

The L u r g i M e t h a n a t i o n P r o c e s s i s u s e d .
(For a d d i t i o n comments, see P a r a g r a p h 3.4.13.)

Process Description

The f e e d g a s i s t h e p u r g e gas f r o m F-T S y n t h e s i s U n i t 250,

from which t h e b u l k o f t h e h i g h e r h y d r o c a r b o n s h a s been
removed i n H y d r o c a r b o n R e c o v e r y U n i t 210 i n o r d e r t o
prevent f o u l i n g of t h e methanation c a t a l y s t .

The m e t h a n a t i o n u n i t c o n s i s t s o f two down-flow, f i x e d - b e d

r e a c t o r s i n s e r i e s . T h e f e e d g a s i s h e a t e d i n 212-E-03, 04,
a n d 05 a g a i n s t t h e s e c o n d r e a c t o r , 212-D-02, p r o d u c t . Steam
i s i n j e c t e d i n t h e f e e d g a s , a n d t h e gas i s a l s o d i l u t e d
w i t h a p o r t i o n of t h e m e t h a n a t e d g a s f r o m t h e f i r s t r e a c t o r ,
212-D-01. The d i l u t i o n gas i s c o m p r e s s e d by R e c y c l e
C o m p r e s s o r 212-C-01, a f t e r h a v i n g b e e n c o o l e d by 212-E-01
a n d 0 2 . kIP steam i s g e n e r a t e d i n 212-E-01.

The n e t r e a c t o r e f f l u e n t f r o m t h e f i r s t r e a c t o r f l o w s t o
t h e second, o r c l e a n - u p , r e a c t o r i n which f i n a l methanation
t a k e s p l a c e . The c l e a n - u p r e a c t o r e f f l u e n t i s h e a t
e x c h a n g e d a g a i n s t t h e gas f e e d a n d c o o l e d i n E x c h a n g e r s
212-E-06 a n d 07.

P r o c e s s water c o n d e n s e d f r o m t h e r e a c t o r e f f l u e n t stream
i s c o l l e c t e d a n d r o u t e d t o BFW p r e p a r a t i o n U n i t 231.
The m e t h a n a t e d gas l e a v e s t h e u n i t f o r f u r t h e r t r e a t i n g
C 0 2 Removal U n i t 213.

-108-
 4.4.6 COz Removal U n i t 2 1 3 (PFD ZO-GEM-6976)

P u r p o s e of t h e U n i t i s t o l o w e r t h e C02 c o n t e n t i n t h e
SNG t o a b o u t 0 . 5 % , t h e r e b y i m p r o v i n g i t s q u a l i t y .

T e c h n o l o g y Used

The Amine Guard P r o c e s s o f Union C a r b i d e C o r p . i s u s e d .

( F o r a d d i t i o n a l comments, see P a r a g r a p h 3 . 4 . 1 4 . )

Process D e s c r i p t i o n

The M e t h a n a t i o n U n i t 212 p r o d u c t g a s a n d t h e l i g h t gases

from F-T P r o d u c t F r a c t i o n a t i o n U n i t 252 a r e c h a r g e d t o
A b s o r b e r 213-D-01, i n w h i c h t h e C 0 2 i s removed by a
c o u n t e r c u r r e n t stream o f l e a n MEA s o l u t i o n . In the top
of t h e absorber, t h e gas is scrubbed w i t h a s m a l l flow
of BFW t o r e c o v e r t r a c e a m o u n t s o f MEA s o l u t i o n . The
p u r i f i e d g a s t h e n f l o w s t o SNG D r y i n g a n d C o m p r e s s i o n
Unit 214.

The a b s o r b e r b o t t o m s p r o d u c t ( r i c h MEA s o l u t i o n ) i s e x p a n d e d
a f t e r h e a t e x c h a n g e i n 213-E-01 i n t o MEA R e g e n e r a t o r 213-D-02,
w h e r e t h e C02 a n d o t h e r c o - a b s o r b e d compounds a r e s t r i p p e d
f r o m t h e MEA s o l u t i o n . The steam i n t h e r e g e n e r a t o r
o v e r h e a d i s c o n d e n s e d i n C o n d e n s e r s 213-E-04 a n d 0 5 , a n d
t h e r e m a i n i n g o f f g a s e s a r e s e n t t o E o i l e r U n i t 222 f o r
incineration. The steam c o n d e n s a t e i s r e f l u x e d t o t h e
t o p o f t h e r e g e n e r a t i o n . The l e a n s o l u t i o n f r o m t h e
bottom o f t h e r e g e n e r a t o r i s pumped b a c k t o A b s o r b e r 213-D-01
a f t e r b e i n g c o o l e d i n 213-E-01, 02 a n d 0 3 .

4.4.7 SNG D r y i n g a n d C o m p r e s s i o n U n i t 214 (PFP ZO-GEM-6976)

P u r p o s e of t h e U n i t i s t o d r y t h e w e t SNG t o a water
c o n t e n t o f 4 lb/bIMSCF a n d t o c o m p r e s s t h e d r i e d SNG f o r
delivery into t h e S N G pipeline system.

T e c h n o l o g y Used

The TEG Wash P r o c e s s , a commercial p r o c e s s f o r d r y i n g

n a t u r a l g a s , is used.

-109-

I
 Process Description

The d r y i n g a g e n t is a m i x t u r e o f t r i e t h y l e n e g l y c o l (TEG)
and o t h e r e t h y l e n e g l y c o l s .

The SNG i s c o n t a c t e d c o u n t e r c u r r e n t l y w i t h l e a n TEG i n

Water A b s o r b e r 214-D-01. The w a t e r - r i c h TEG f l o w s
from t h e a b s o r b e r t o TEG R e g e n e r a t o r 214-D-02 w h i c h i s
h e a t e d by f u e l g a s . The steam s t r i p p e d f r o m t h e TEG i s
d i s c h a r g e d t o t h e atmosphere. The s m a l l r e f l u x stream
r e q u i r e d i s c o n d e n s e d w i t h i n t h e v e n t t u b e by a i r c o o l i n g .

The r e g e n e r a t e d TEG i s s t o r e d i n 214-F-01, w h e r e i t is

cooled by t h e r i c h TEG b e f o r e b e i n g pumped i n t o t h e t o p
of Water A b s o r b e r 214-D-01.

The d r i e d SNG i s c o m p r e s s e d by 214-C-01 for delivery into

t h e SNG p i p e l i n e s y s t e m .

4.4.8 Fischer-Tropsch S y n t h e s i s U n i t 250 (PFD 20-GEM-6977)

P u r p o s e of t h e U n i t is t o s y n t h e s i z e h y d r o c a r b o n s by
r e a c t i n g h y d r o g e n a n d c a r b o n monoxide.

T e c h n o l o g y Used

S i n c e t h e e a r l y 2 0 ’ s when F i s c h e r a n d T r o p s c h p r o d u c e d
h i g h e r h y d r o c a r b o n s f r o m c a r b o n monoxide a n d h y d r o g e n ,
t h e amount o f r e s e a r c h a n d d e v e l o p m e n t i n t h e f i e l d o f
c a r b o n monoxide h y d r o g e n a t i o n h a s b e e n o v e r w h e l m i n g .
Today, t h i s c h e m i s t r y can p r o d u c e a f u l l r a n g e o f
p e t r o c h e m i c a l and o i l p r o d u c t s , i n c l u d i n g methane
( m e t h a n a t i o n ) , methanol, and l i q u i d hydrocarbons and
waxes ( F i s c h e r - T r o p s c h ) . B e f o r e 1 9 4 0 , c o m m e r c i a l
F i s c h e r - T r o p s c h p l a n t s were o p e r a t i n g i n Germany, F r a n c e
and Japan. Low p r i c e c r u d e o i l a f t e r World War I1
p r e c l u d e d a n y f u r t h e r c o m m e r c i a l u s e o f F-T t e c h n o l o g y ,
t h e exception being Sasol i n Sasolburg, South A f r i c a .
T h i s p l a n t , completed i n 1955, is s t i l l i n o p e r a t i o n
( S a s o l I ) and a large e x p a n s i o n i s c u r r e n t l y i n p r o g r e s s
(Sasol 11). I t is t h e Sasol technology, as r e p o r t e d i n
t h e l i t e r a t u r e , which is t h e t e c h n i c a l b a s i s f o r U n i t 250
development.

A l t h o u g h a t y p i c a l F-T p r o d u c t i s a c o m p l i c a t e d m i x t u r e ,
t h e following overall equations i l l u s t r a t e the process:

nC0 + 2nH2 L(-CH2-)n + nH2O

hydrocarbon

2nCO + nH2 -(-CHz-)n + nC02

hydrocarbon

-110-
 nCO + 2nH2 \ H(-CH2-)n OH + ( n - 1 ) H20
alcohol

a n d l i n k a g e water gas s h i f t r e a c t i o n
CO + H20 / '
H2 +- C02

T h e s e e q u a t i o n s do n o t i n d i c a t e t h e r e a c t i o n m e c h a n i s m ,
b u t t h e y do show t h e s t o i c h i o m e t r i c r e l a t i o n s h i p between
r e a c t a n t s and p r o d u c t s . E x c e p t f o r t h e water gas s h i f t
r e a c t i o n , a l l r e a c t i o n s a r e h i g h l y e x o t h e r m i c . The F-T
p r o d u c t i n c l u d e s p a r a f f i n s , mono-olefins, aromatics,
a l c o h o l s , a l d e h y d e s , k e t o n e s and f a t t y a c i d s w i t h c a r b o n
numbers f r o m 1 t h r o u g h 35+. S m a l l a m o u n t s of d i o l e f i n s
and e s t e r s c a n a l s o b e p r o d u c e d . B r a n c h i n g d o e s o c c u r
b u t it is predominantly a s i n g l e - m e t h y l branched s t r u c t u r e
Y i e l d s e l e c t i v i t y and composition is h i g h l y dependent
upon t h e c a t a l y s t , r e a c t i o n c o n d i t i o n s a n d r e a c t o r t y p e .

Commercial c a t a l y s t s i n c l u d e c o b a l t ( f i x e d - b e d ) a n d i r o n
(fixed-and fluid-bed.) Both are promoted f o r improved
a c t i v i t y and s e l e c t i v i t y . O p e r a t i n g c o n d i t i o n s range
from 2 0 0 t o 325OC a n d f r o m a t m o s p h e r i c t o 2 5 a t m p r e s s u r e ,
d e p e n d i n g upon p r o d u c t s d e s i r e d , c a t a l y s t a n d r e a c t o r
d e s i g n . F o r e x a m p l e , c o n d i t i o n s f o r t h e S a s o l I medium
p r e s s u r e u n i t s a r e r e p o r t e d t o be ( 1 5 ) :

Type Fixed-Bed F l u i d-Bed

C a t a l y s t Base Fe Fe
Temperature, OC 220-255 320-330
Pressure, psig 360 330

Although i r o n i s t h e b a s e f o r both u n i t s , c a t a l y s t
p r e p a r a t i o n and f o r m u l a t i o n are e n t i r e l y d i f f e r e n t and
very s p e c i f i c f o r each u n i t type.

The p r i n c i p a l problem i n d e s i g n i n g t h e r e a c t o r i s h e a t
r e m o v a l . F i x e d - b e d r e a c t o r d e s i g n s a r e some f o r m of a
h e a t e x c h a n g e r w i t h c a t a l y s t b e i n g c o o l e d by b o i l i n g
water o r c i r c u l a t i n g o i l . F l u i d - b e d r e a c t o r s i n c l u d e
i n t e r n a l t u b e bundles f o r r e a c t i o n h e a t removal.

As s t a t e d p r e v i o u s l y , U n i t 2 5 0 is b a s e d o n S a s o l - t y p e
fluid-bed technology, d e r i v e d mainly from r e f e r e n c e s
c i t e d which i n c l u d e b o t h S a s o l a r t i c l e s a n d t h o s e
r e p o r t i n g o n S a s o l o p e r a t i o n . The p r o j e c t e d commercial
f l u i d - b e d process d e s i g n c o n d i t i o n s a n d y i e l d s a r e a s
follows :
1. F e e d R a t i o H2/(2C0 + 3CO2) = 1 . 0 3 Ratio is critical. (9) (12)

-111-
2. Basic y i e l d s ( 7 ) ( 8 )
C ,atoms H atoms* H 2 0 atoms*

C1 10 40.00
C0= 4 8.00
c; 6 18.00
c 3= 12 24.00
c3 2 5.33
c4=
~
8 16.00
1 2.50
c4
c5 p l u s 8 16.50 -
light o i l 35 69.30 1.25
heavy o i l 7 13.84 0.08
a1coho 1s 6 11.28 2.70
acids - 1 0.21 0.90
100 224.96 4.93

-
CO + H 2 HC, A l c & Acid + H20
100 112.48 = 4.93 1 0 0 - 4 . 9 3 lb-mol
H20
- 100.00 c = 100
H2 = 112.48
100 + 2 1 2 . 4 8 217.41 + 95.07 lb-mol

* E s t i m a t e d b y MRDC.

3. Y i e l d s a d j u s t e d by MRDC t o o b t a i n 8 5 . 0 % c o n v e r s i o n
of (CO + H 2 ) ( 8 )

-
CO: 17,806.5 lb-mol/hr r e a c t e d = 96.25% conversion

-
H2: 37,857.6 lb-mol/hr reacted = 80.57% c o n v e r s i o n
5 5 , 6 6 4 . 1 lb-mol/hr reacted = 85.0% conversion

CO + H2 HC, A l c & A c i d + H20

17,806.5 37,857.6 _13_) 16,927.7 lb-mOl/hr
498,760.1 76,320.9 270,111.6 304,969.4 l b / h r

e1I
28,843.6 l b / h r
c2= 10,087
c2 16,219
c3= 30,262
c3 5,285
c4= 20,175
c4 2,612
c5 plus 21,196
light o i l 89,397
heavy o i l 17,181
a1coho 1s 23,744
acids 5,110
270,111.6

A d e t a i l e d y i e l d breakdown i s p r e s e n t e d i n T a - , l e 1
.4.1.

-112-
 TABLE 4.4.1
FISCHER-TROPSCH COXVERSION UNIT 250
PRODUCT COWOSITION
c
Syn Gas From From b o r n 'tom
Feed , F e e d Gas, React Ion, .ght Oil [eavp O i l Total , Qtll,
:omponent Ldpl Ib/hr Ibf h r Ib/hr )), 1 b/hr ,4),lb/hr lbfhr b-mol/hr
28.02 8,658.2 8,658.2 8,658.2 309.0
44.01 27,629.0 136,871.1 136,871.1 3,110.0
28.01 18,185.0 13,542.8 13,542.8 483.5
2.016 94,721.8 18,824.2 16,824.2 9,337.4
16.04 99,858.4 199,858.4 28,843.6 228,702.0 14,258.2
28.05 589.0 589.0 10,087.O 10,676.0 380.6
30.07 8,329.4 8,329.4 16,219.0 40.2 24,588.6 817.7
42.08 30,262.0 1 ,099.6 31,361.6 745.3
44.09 5,285.0 201.2 5,486.2 124.4
56.10 19,036.0 2,145.S 21,181.5 377.6
56.10 1,139.0 134.1 1,273.1 22.7
58.12 2,612.O 402.3 3,014.3 51.9
70.13 7,690..0 3,754.7 11,444.7 163.2
70.13 3,204.0 1,564.4 4,768.4 68.0
72.15 (2) 1,922.0 938.7 2,860.7 39.6
84.16 21 ,'196.0 3,684.0 4,337.4 8,021.4 95.3
04.16 2,210.0 2,602.4 4,812.4 57.2
86.17 1,473.0 1,734.9 3,207.9 37.2
97 1,013.0 8,824.9 9,037.9 101.4
2 50 110 15,329.4 15,329.4 139.4
300 127f 122 8,330,O 527.7 8,857.7 69.9
350 144 (3) 13,345.0 13,345.0 82.7
4 00 1651163 89,397.0 6,740.4 627.4 7,367.8 44.6
4 50 187 9,812.9 9,812.9 52.5
500 2111210 2,977.5 1,627.1 4,604.6 21.8
550 238f 232 5,081.5 993.7 6,075.2 25.7
600 260 3,185.0 2,185.0 0.4
650 288 1,707.9 1,707.9 5.9
700 315 (4) 2,944.1 2,944.1 9.3
750 350 17,181.0 2,109.8 2,199.8 6.3
800 380 1,424.7 1,424.7 3.7
850 409 1,082.7 1,082.7 2.6
900 440 366.7 366.7 0.3
1,000 Plus 510 1,404.2 1,494.2 2.9
Alcohol8 51.34 0.0 42.0 23,744.0 23,786.0 463.3
Acids 65.20 5,110.0 5,110.0 78.3
H20(1) 18.C.10 301.,186.1 301 166.1 16,717.7
358,012.8 386.715.1 571.297.7
(958,012.8)
89,397.6 rn 958.01218 a6,326.0
4. L i g h t a n d h e a v y o i l c a r b o n atom d i s t r i b u t i o n a n d
d i s t i l l a t i o n , a l c o h o l y i e l d breakdown, and a c i d
y i e l d breakdown are f r o m Reference 7 .

5. Reactor d e s i g n p a r a m e t e r s u s e d a r e :
- H e a t o f r e a c t i o n (MRDC e s t i m a t e ) : 4,550 Btu/lb t o t a l
product

- Fresh feed charge: 2 0 7 MNm3/hr p e r r e a c t o r .

The l i t e r a t u r e , ( 1 0 ) gt (14), r e f e r s t o a s e c o n d g e n e r a t i o n
f l u i d - b e d r e a c t o r b e i n g f r o m 2 t o 3 t i m e s t h e s i z e of
Sasol I . Reference 8 used a Sasol I r e a c t o r scale-up
of 2 i n t h e i r s t u d y . U s i n g R e f e r e n c e 8 as t h e b a s i s ,
t h e above charge rate p e r r e a c t o r r e p r e s e n t s a scale-up
of 2 . 1 . F i v e r e a c t o r s a r e employed w i t h o n e b e i n g a
spare.

- R e c y c l e mole r a t i o ( 1 5 ) : 2/1

- Catalyst f i l l (MRDC e s t i m a t e f r o m ( 9 ) ( 1 2 ) ) :
335 metric . t o n s p e r r e a c t o r .

- Operating conditions (7)

v a p o r feed t e m p e r a t u r e : 16OoC
c a t a l y s t and vapor o u t l e t temperature: 34OoC
vapor o u t l e t pressure: 300 p s i a

- Catalyst life (7) (8): 50 d a y s

Process Description

The s y n t h e s i s gas f r o m P u r i f i c a t i o n U n i t 2 0 5 a n d t h e
r e c y c l e gas a r e c o m p r e s s e d t o g e t h e r i n C o m p r e s s o r 250-C-01,
heat e x c h a n g e d a g a i n s t a p o r t i o n o f t h e r e a c t o r e f f l u e n t
i n E x c h a n g e r 250-E-01 a n d charged t o t h e f l u i d - b e d Reactor
250-D-01. A f t e r mixing w i t h t h e c i r c u l a t i n g h o t Fe
c a t a l y s t , r e a c t i o n t a k e s p l a c e as t h e m i x t u r e f l o w s up
t h e reactor t h r o u g h t u b e b u n d l e s i n w h i c h o i l i s pumped
(250-G-01) f o r h e a t r e m o v a l ( t e m p e r a t u r e c o n t r o l ) . A t
t h e t o p of t h e r e a c t o r , t h e mixture enters a l a r g e
v e s s e l i n which c y c l o n e s are i n s t a l l e d f o r i r o n / v a p o r
s e p a r a t i o n . The h o t o i l i s c i r c u l a t e d t o Steam Generat,or
250-E-02 w h e r e 200 p s i g steam i s p r o d u c e d .

-114-
 Because o f t h e e x p e c t e d f o u l i n g n a t u r e of ;he r e a c t g r
e f f l u e n t , i t is washed a n d c o o l e d f r o m 6 4 5 F t o 340 F i n
E f f l u e n t Wash Tower 250-D-02 by a r e c y c l e stream f r o m
6UJ t h e b o t t o m s o f Vapor C o l d Wash Tower 250-D-03. A
r e l a t i v e l y c l e a n , h o t stream is w i t h d r a w n f r o m E f f l u e n t
Wash Tower 250-D-02 f o r c o o l i n g . I t s heat is used f o r
h e a t i n g t h e r e a c t o r v a p o r f e e d (250-E-01), b o i l e r f e e d
water h e a t i n g (250-E-06) a n d LP steam g e n e r a t i o n
(250-E-07 a n d 0 8 ) . A h o t heavy o i l i s w i t h d r a w n f r o m t h e
bottom and s e n t t o F r a c t i o n a t i o n U n i t 252.

The o v e r h e a d v a p o r i s c o o l e d i n BFW E x c h a n g e r 250-E-03

a n d C o n d e n s e r s 250-E-04 a n d 0 5 . I t is t h e n water washed
i n Wash Tower 250-D-03. The o v e r h e a d v a p o r i s s p l i t
i n t o r e c y c l e a n d p u r g e gas streams. The l a t t e r i s s e n t
t o H y d r o c a r b o n R e c o v e r y U n i t 2 1 0 . The c o n d e n s e d l i q u i d
i s a l s o s p l i t i n t o 2 streams: c o l d r e c y c l e t o Tower
250-E-02 a n d l i g h t o i l p r o d u c t t o Wash Tower 250-D-04
f o r f i n a l water w a s h i n g . T h e l i g h t o i l i s s e n t t o
F r a c t i o n a t i o n Unit 252. The u s e d w a s h w a t e r , c o n t a i n i n g
t h e a l c o h o l s and a c i d s from t h e Fischer-Tropsch r e a c t i o n ,
flows t o Alcohol Recovery Unit 262.

4.4.9 N a p h t h a H y d r o t r e a t i n g U n i t 2 5 1 (ZO-GEM-6974)

Purpose of t h e U n i t is y i e l d a c l e a n , s a t u r a t e d s t a b i l i z e d
naphtha f o r g a s o l i n e p o o l b l e n d i n g from t h e r a w g a s i f i e r
naphtha.

T e c h n o l o g y Used

See Paragraph 3.4.17.

Process Description

I d e n t i c a l t o U n i t 151. See Paragraph 3.4.17.

4.4.10 F-T P r o d u c t F r a c t i o n a t i o n U n i t 252 (ZO-GEM-6978)-

P u r p o s e of t h e U n i t i s t o s e p a r a t e t h e F-T reactor
product i n t o l i g h t gases, feedstocks f o r t h e polymerization
a n d h y d r o g e n a t i o n u n i t s a n d a 550+ r e s i d u u m f o r b o i l e r
fuel.
T e c h n o l o g y Used

Because of t h e u n c e r t a i n i t y a s t o t h e e f f e c t o f steam
on t h e r e m a i n i n g a l c o h o l s a n d a c i d s , a 4 - t o w e r , d r y
s y s t e m is u s e d .

c.$ -115-
 Process Description

The h e a v y o i l i s h e a t e d i n F u r n a c e 252-B-01, f l a s h e d
i n D r u m 252-F-01, a n d cha.rged t o 'Jacuum Tower 252-D-01.
Vacuum i s m a i n t a i n e d by 252-C-01. The tower h a s a n
u p p e r pump-around s y s t e m . The o v e r h e a d v a p o r s a n d
e x c e s s pump-around l i q u i d a r e c o n d e n s e d / c o o l e d i n
C o n d e n s e r 252-E-03 a n d pumped (252-G-15) t o t h e t o p o f
A b s o r b e r / D e e t h a n i z e r 252-D-02. Vacuum r e s i d u e ( b o t t o m s )
i s pumped (252-G-03) t o B o i l e r U n i t 2 2 2 .

F e e d t o A b s o r b e r D e e t h a n i z e r 252-D-02 c o n s i s t s of (1)
l i g h t o i l from U n i t 2 5 0 , ( 2 ) h y d r o c a r b o n s r e c o v e r e d i n
U n i t 2 1 0 , ( 3 ) vacuum tower o v e r h e a d , a n d ( 4 ) l e a n o i l
f r o m Naphtha S p l i t t e r 252-D-04. The h y d r o c a r b o n stream
from U n i t 210 i s f i r s t f l a s h e d i n Drum 252-F-03. The
absorber d e e t h a n i z e r h a s a n u p p e r a n d m i d d l e pump-around
systems. The l i g h t g a s e s a r e s p l i t i n t o a f u e l g a s
stream a n d a f e e d stream t o C02 Removal U n i t 2 1 3 i n t h e
SPJG t r a i n . The d e e t h a n i z e r bottoins a r e s e n t t o D e b u t a n i z e r
252-D-03.

I n 252-D-03, t h e propene/butene feed f o r Polymerization

Unit 257 i s obtained. The debutanizer uses a f i r e d
r e b o i l e r , 252-B-02.
The d e b u t a n i z e r b o t t o m s , a f t e r c o o l i n g i n Cooler 212-E-11,
i s c h a r g e d t o S p l i - t t e r 252-D-04, i n w h i c h naphtha. i s
removed t o o b t a i n a h e a v i e r l e a n o i l for r e c y c l i n g t o
A b s o r b e r D e e t h a n i z e r 252-D-02. The tower bottoms ( l e a n
o i l ) a n d t h e o v e r h e a d n a p h t h a a r e r e c o m b i n e d t o become
t h e f e e d s t o c k f o r H y d r o g e n a t i o n Unit. 2 5 3 . The n a p h t h a
s p l i t t e r a l s o u s e s a f i r e d r e b o i l e r , 252-B-03.

4.4.11 F . T . P r o d u c t H y d r o t r e a t i n g U n i t 253 (20-GEM-6979)

P u r p o s e of t h e U n i t i s t o s a t u r a t e t h e o l e f i n s a n d
t o d e s t r o y t h e remaining a l c o h o l s and a c i d s .

T e c h n o l o g y Used

See Paragraph 3.4.17.

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 Process D e s c r i p t i o n
The f e e d is pumped t o r e a c t o r o p e r a t i n g p r e s s u r e
c3 (253-G-01), mixed w i t h p a r t o f t h e h y d r o g e n f e e d , h e a t
exchanged against t h e reactor e f f l u e n t i n Exchanger
253-E-01, and f i n a l l y h e a t e d t o r e a c t o r o p e r a t i n g
t e m p e r a t u r e i n Heater 253-B-01. Because of t h e h i g h
h y d r o g e n c o n s u m p t i o n , Reactor 253-D-01 c o n s i s t s o f
m u l t i - b e d s u s i n g a c o l d hydrogen quench f o r t e m p e r a t u r e
c o n t r o l . A t w o - s t a g e f l a s h s y s t e m is u s e d : High Temp.
F l a s h Drum 253-F-01 a n d Low Temp. F l a s h Drum 253-F-02.
L i q u i d p r o d u c t s a r e combined t o become f e e d t o F r a c t i o n a -
t i o n U n i t 2 5 4 . The h y d r o g e n - r i c h g a s e s f r o m Drum
253-F-02 a r e s p l i t i n t o h y d r o g e n r e c y c l e a n d h y d r o g e n
f e e d f o r P o l y G a s o l i n e H y d r o g e n a t i o n U n i t 2 5 9 . The
h y d r o g e n r e c y c l e i s c o m p r e s s e d i n C o m p r e s s o r 253-C-01,
a n d t h e n mixed w i t h t h e make-up h y d r o g e n . R e a c t i o n
water c o l l e c t e d i n t h e low t e m p e r a t u r e drum i s s e n t t o
Waste Water T r e a t m e n t U n i t 2 3 5 .
Regeneration f a c i l i t i e s f o r t h e hydrotreating c a t a l y s t
are p r o v i d e d .
4.4.12 H y d r o t r e a t e r P r o d u c t F r a c t i o n a t i o n U n i t 254 (ZO-GEM-6979)

Purpose of t h e U n i t is t o s e p a r a t e t h e hydrotreated
p r o d u c t i n t o a p e n t a n e / h e x a n e stream f o r i s o m e r i z a t i o n ,
a C7/380 n a p h t h a f o r r e f o r m i n g , a d i e s e l o i l p r o d u c t a n d
a heavy f u e l o i l p r o d u c t .
T e c h n o l o g y Used

A c o n v e n t i o n a l 3-tower s y s t e m is u s e d .

Process D e s c r i D t i o n

A f t e r h e a t i n g i n H e a t e r 254-B-01, t h e h y d r o t r e a t e r
p r o d u c t i s c h a r g e d t o hlain F r a c t i o n a t o r 254-D-01, i n
w h i c h s t r i p p i n g steam i s i n t r o d u c e d a t t h e bottom. The
heavy' f u e l o i l p r o d u c t i s w i t h d r a w n f r o m t h e bottom a n d
a f t e r c o o l i n g s e n t t o s t o r a g e . A s m a l l amount o f x h e
heavy f u e l o i l , Stream 1 7 3 . 2 , h a s been used i n t h e f i n a l
a d j u s t m e n t of t h e p l a n t f u e l b a l a n c e . A s i d e - c u t is
w i t h d r a w n t o S t e a m S t r i p p e r 254-D-02 f r o m w h i c h t h e d i e s e l
o i l p r o d u c t , a f t e r c o o l i n g , is pumped t o s t o r a g e .
The l i g h t g a s e s , b u t a n e s , p e n t a n e s / h e x a n e s , n a p h t h a a n d
steam i n t h e o v e r h e a d p r o d u c t a r e cooled i n C o n d e n s e r s
254-E-01 a n d 0 2 , a n d s e p a r a t e d i n R e f l u x Drum 254-F-01.
L i g h t g a s e s become a f e e d t o L i g h t Ends R e c o v e r y U n i t 2 6 0 .
Water i s pumped (254-G-09) t o Waste Water T r e a t m e n t U n i t 2 3 5
The h y d r o c a r b o n l i q u i d i s s p l i t i n t o r e f l u x f o r t h e m a i n
f r a c t i o n a t o r a n d f e e d f o r D e b u t a n i z e r 254-D-03.

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 I n t h e d e b u t a n i z e r , e s s e n t i a l l y a l l t h e b u t a n e s are
recovered a n a s e n t t o L i g h t Ends U n i t 2 6 0 . T h e
d e b u t a n i z e r b o t t o m s are c h a r g e d t o Naphtha S p l i t t e r
254-D-04. I n t h e s p l i t t e r , t h e pentanes and hexanes
are f r a c t i o n a t e d f r o m t h e heavy n a p h t h a , or r e f o r m e r
c h a r g e a n d a f t e r c o o l i n g pumped (254-G-07) t o
I s o m e r i z a t i o n U n i t 2 5 6 . The c o o l e d h e a v y n a p h t h a i s
pumped (254-G-08) t o R e f o r m i n g U n i t 2 5 5 .

4.4.13 C a t a l y t i c R e f o r m i n g U n i t 2 5 5 (20-GEM-6980)

P u r p o s e of t h e U n i t i s t o i n c r e a s e t h e a n t i - k n o c k
q u a l i t y of t h e C 7 / 3 8 0 n a p h t h a .

T e c h n o l o g y Used

S i n c e i t s commercial i n t r o d u c t i o n i n 1 9 5 0 , c a t a l y t i c
r e f o r m i n g w i t h p l a t i n u m - b a s e d c a t a l y s t s h a s become t h e
m a j o r p r o c e s s f o r n a p h t h a o c t a n e improvement ( a n d
aromatics production) i n t h e petroleum industry.
Reactions include: (1) d e h y d r o g e n a t i o n o f n a p h t h e n e s ,
( 2 ) c y c l i z a t i o n of s t r a i g h t - c h a i n p a r a f f i n s and subsequent
dehydrogenation, ( 3 ) i s o m e r i z a t i o n of p a r a f f i n s and
c y c l o p e n t a n e d e r i v a t i v e s a n d ( 4 ) hydrocracking of
p a r a f f i n s a n d n a p h t h e n e s . The f o r m a t i o n o f a r o m a t i c s
is t h e p r i n c i p a l o b j e c t i v e .
C a t a l y t i c r e f o r m i n g is c a r r i e d o u t o v e r a w i d e r a n g e of
r e a c t i o n c o n d i t i o n s , t h e most i m p o r t a n t b e i n g p r e s s u r e .
Other v a r i a b l e s include recycle gas rate, temperature,
s p a c e v e l o c i t y a n d c a t a l y s t p a r t i c l e s i z e . Thermo-
d y n a m i c a l l y , d e h y d r o g e n a t i o n i s f a v o r e d by low p r e s s u r e
and h i g h t e m p e r a t u r e s . These c o n d i t i o n s , however, also
f a v o r t h e formation of coke. F o r t u n a t e l y , coke formation
c a n be s u b s t a n t i a l l y s u p p r e s s e d by o p e r a t i n g i n a n
atmosphere of hydrogen w i t h o u t s i g n i f i c a n t r e t a r d a t i o n
of t h e d e h y d r o g e n a t i o n r e a c t i o n s . T y p i c a l r e a c t o r
c o n d i t i o n s are:

Pressure, psig 100-700

R e c y c l e gas, SCF/Bbl 2,500-10,000
Temperature, O F 850-1,000
Space v e l o c i t y , w t / h r / w t 1-3
In recent years, b i m e t a l l i c c a t a l y s t s - platinum p l u s
o t h e r metal p r o m o t o r s , s u c h a s r h e n i u m - h a v e b e e n
commercialized. T h e i r improved s e l e c t i v i t y and a c t i v i t y
permit r e f o r m i n g a t l o w e r p r e s s u r e s a n d h i g h e r s e v e r i t i e s ,
w i t h o u t s h o r t e n i n g r e g e n e r a t i o n c y c l e t i m e s , t h a n when
u s i n g t h e p r e v i o u s s t a n d a r d platinum-on-alumina c a t a l y s t .

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The principal problem in the design of catalytic
reformers is heat balance. Reactions which produce
aromatics are very endothermic. Although the
exothermic hydrocracking reactions are partially
offsetting, large amounts of heat must be supplied
to the reaction zone. In fixed-bed units, the heat
is supplied by employing multiple reactors in series
with intermediate reheating of the reactants. As
conditions dictate, a unit may be designed to operate
either in a cyclic-or semi-regenerative mode of
operation.
Most feedstocks are hydrotreated first to remove arsenic,
sulfur and nitrogen compounds. Otherwise, these
materials would poison the platinum catalyst. The cost
of hydrotreating is easily justified b y the extension
of the reforming catalyst life.
Commercial processes are licensed by IFP, UOP Process,
Houdry, Exxon, Chevron Research and Standard Oil
(Indiana).
Process Description
The naphtha feed is pumped (255-G-04) to reactor
operating pressure, mixed with the hydrogen-rich recycle
gas, heat exchanged against Reactor 255-D-03 effluent
in Exchanger 255-E-01 and heated to reactor operating
temperature in Heater 255-B-01. The naphtha/hydrogen
mixture then flows through three reactors in series,
255-D-01, 02 and 03, and is reheated before the second
and third reactors in Heaters 255-B-02 and 03.
The third reactor effluent is cooled in 255-01, 02 and
03 and flashed in Drum 255-F-01. The hydrogen-rich
overhead is split into a recycle gas stream and a feed
stream to H 2 Purification Unit 261. The bottoms are
pumped (255-G-03) to Stabilizer 255-D-04 for light
ends fractionation. The butanes and lighter are sent
to Light Ends Unit 260. After cooling, the stabilized
reformate is sent to Gasoline Blending Unit 270.
Off-stream regeneration facilities are provided.

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- -

4.4.14 C -6 ; / C -P I s o m e r i z a t i o n U n i t 256 (ZO-GEM-6981)

P u r p o s e of t h e U n i t i s t o i n c r e a s e t h e a n t i - k n o c k
q u a l i t y o f t h e p e n t a n e s and h e x a n e s . Besides r a i s i n g
t h e p o o l o c t a n e , i n c r e a s i n g t h e o c t a n e of t h e l i g h t e r
g a s o l i n e c o n s t i t u e n t s improves t h e o c t a n e b a l a n c e
b e t w e e n t h e f r o n t a n d back e n d s o f t h e g a s o l i n e b l e n d .

T e c h n o l o g y Used

The f i r s t c o m m e r c i a l i s o m e r i z a t i o n u n i t s f o r t h e
improvement o f m o t o r g a s o l i n e were a n n o u n c e d i n 1957.
Isomerization r e q u i r e s t h e use of a c a t a l y s t . There
is l i t t l e h e a t e v o l v e d , a n d t h e r e a c t i o n i s l i m i t e d by
e q u i l i b r i u m and r a t e c o n s i d e r a t i o n s . An e c o n o m i c
b a l a n c e i s made between h i g h e r b r a n c h e d - c h a i n r a t i o s
a t l o w t e m p e r a t u r e s and h i g h e r r e a c t i o n rates a t h i g h
temperatures. S i d e r e a c t i o n s a l s o must b e c o n s i d e r e d
i n t h e s e l e c t i o n of c o n d i t i o n s .
Platinum-containing c a t a l y s t s are favored i n c u r r e n t
commercial p r o c e s s e s . They a r e p r o m o t e d by t h e i n j e c t i o n
o f t r a c e a m o u n t s o f o r g a n i c c h l o r i d e . T h e a d d i t i o n of
a s m a l l amount o f h y d r o g e n suppresses t h e p o l y m e r i z a t i o n
of t h e t r a c e s o f o l e f i n s f o r m e d d u r i n g t h e i s o m e r i z a t i o n
r e a c t i o n and t h e formation of coke d u r i n g hydrocracking
reactions. Specifications f o r feedstock impurities,
e . g . , s u l f u r , water, benzene and C 7 ' s , vary c o n s i d e r a b l y
between t h e commercial p r o c e s s e s . L i c e n s o r s , however,
h a v e i n r e c e n t y e a r s improved s i g n i f i c a n t l y i m p u r i t y
t o l e r a n c e s . Although o p e r a t i n g c o n d i t i o n s chosen
g e n e r a l l y a l l o w a c a t a l y s t l i f e o f two o r more y e a r s ,
s h o u l d a c c i d e n t a l d e a c t i v a t i o n o c c u r , t h e c a t a l y s t can
be e a s i l y r e g e n e r a t e d a n d r e a c t i v a t e d t o f u l l a c t i v i t y .

T y p i c a l react i o n c o n d i t i o n s a r e :
Temperature, OF 250-550
Pressure, psig 200-500
Space v e l o c i t y , v o l / h r / v o l 1-5
H 2 / h y d o r c a r b o n mole r a t i o 0.5-4

P r o c e s s i n g c o n d i t i o n s are g e n e r a l l y m i l d e r f o r butane
i s o m e r i z a t i o n t h a n f o r p e n t a n e o r hexane i s o m e r i z a t i o n .

Commercial p r o c e s s e s a r e l i c e n s e d by BP T r a d i n g , S h e l l
R e s e a r c h a n d UOP P r o c e s s .

n
-120-
 Process Description
To maximize the octane improvement, Isomerization Unit 256
3 includes n-pentane recycling. The c5/c6 product from
Unit 254 and the pentane products from isomerization are
fed to Deisopentanizer 256-D-01. The overhead product,
pentane isomerate, also contains the butanes and iso-
pentane in the fresh feed and from 3 to 5 vol. %
' of n-pentane.
After cooling, it is sent to Gasoline Blending Unit 270.
The n-pentane/hexane bottoms are mixed with recycle and
make-up hydrogen, heated via Exchanger 256-D-04 and
Heater 256-D-01 and passed over the catalyst in Reactor
256-D-02. The reactor effluent is cooled and flashed in
Separator 256-F-02. A hydrogen-rich offgas is obtained
for recycling via Compressor 256-G-01 and for hydrogen
recovery in Unit 211.
The separator liquid is sent to Stabilizer 256-D-03 where
the butanes and lighter are fractionated. The stabilizer
offgases from Reflux Drum 256-F-03 after caustic washing
are sent to H2 Purification Unit 261, and the excess
reflux to Light Ends Recovery Unit 260.
The stabilizer bottoms are charged to Depentanizer 256-D-04.
The overhead product is pumped (256-G-04) to the
deisopentanizer for recovery of the recycle n-pentane
The tower bottoms, hexane isomerate, after cooling, are
sent to Gasoline Blending Unit 270.
4.4.15 Catalytic Polymerization Unit 257 (ZO-GEM-6982)
Purpose of the Unit is to polymerize the propene/butene
mixture from the Fischer-Tropsch reaction into higher
molecular weight compounds which are suitable for
gasoline blending.
Technology Used
Catalytic polymerization has been a commercial process
since about 1934 for the conversion of C olefins
9
into a higher molecular weight poly gas0 ine
""d% ith a
propene feed, trimers predominate and with a butene
feed, dimers are the major products. Since the advent
of catalytic reforming yielding a source of iso-butane,
however, polymerization has generally been replaced by
alkylation.

-121-
O l e f i n p o l y m e r i z a t i o n i s c a t a l y z e d by a c i d s a n d
c o n v e r s i o n s a r e 85% o r b e t t e r . T h e r e i s a l a r g e
e x o t h e r m i c h e a t o f r e a c t i o n - a b o u t 400 B t u / l b of
b u t e n e a n d a b o u t 6 7 0 B t u / l b o f p r o p e n e -, a n d a
r e c y c l e stream i s o f t e n u s e d f o r t e m p e r a t u r e c o n t r o l .
Commercial c a t a l y s t s a r e m a i n l y p h o s p h o r i c a c i d on
s o l i d s , s u c h as k i e s e l g u h r and q u a r t z c h i p s .

The w a t e r c o n t e n t o f t h e f e e d i s c r i t i c a l . Optimum
c o n c e n t r a t i o n , however, d i f f e r s w i t h t h e c a t a l y s t
t y p e , r e a c t o r o p e r a t i n g c o n d i t i o n s and f e e d composition.
The o l e f i n f e e d c a n be e i t h e r " d r i e d " , s a t u r a t e d w i t h
water a t a c o n t r o l l e d t e m p e r a t u r e , o r mixed w i t h
i n j e c t e d water.
The p r i n c i p a l r e a c t o r d e s i g n p r o b l e m i s t e m p e r a t u r e
control. Nulti-beds w i t h l i q u i d quench o r t u b u l a r
h e a t e x c h a n g e r r e a c t o r s g e n e r a t i n g steam a r e u s e d .
T y p i c a l o p e r a t i n g c o n d i t i o n s are:

Temperature, OF: 300 - 425

Pressure, psig: 400 - 1,500
Space v e l o c i t y ,
G a 1/ h r / '1b : 0.1 - 0.5

UOP P r o c e s s a n d Chevron Research o f f e r p r o c e s s e s for

licensing.

Process Description

The c a t p o l y f e e d is pumped (257-G-01) t o water

s a t u r a t i o n p r e s s u r e a n d s a t u r a t e d i n Water S e t t l e r
257-F-01. B e c a u s e o f t h e h i g h c o n c e n t r a t i o n of o l e f i n s ,
o n l y a p o r t i o n o f t h e f r e s h f e e d i s mixed w i t h t h e low
o l e f i n containing recycle stream, heated t o reaction
t e m p e r a t u r e i n E x c h a n g e r 257-E-01 a n d Heater 257-E-02,
a n d c h a r g e d t o t h e i n l e t of R e a c t o r 257-D-01. The
r e m a i n i n g c o o l f r e s h feed a n d , i f n e e d e d , r e c y c l e a r e
used a s a q u e n c h f o r i n t e r b e d c o o l i n g .
A f t e r p a s s i n g t h r o u g h A c i d K . O . Drum 257-F-02 a n d
Heat E x c h a n g e r 257-E-01, t h e r e a c t o r e f f l u e n t i s s p l i t
i n t o t h e r e c y c l e stream a n d t h e f e e d f o r D e b u t a n i z e r
257-D-02. T h e o v e r h e a d p r o d u c t , c o n s i s t i n g of u n r e a c t e d
o l e f i n s , iso-butane and i n e r t propane and n-butane, is
c o o l e d a n d pumped t o A l k y l a t i o n U n i t 2 5 5 . The p o l y
g a s o l i n e ( b o t t o m s ) i s s e n t t o S p l i t t e r 257-D-03, w h e r e
i t i s s e p a r a t e d a t t h e Cg - C 1 o b o i l i n g r a n g e . T h e
l i g h t p o l y g a s o l i n e i s pumped (257-G-03) t o G a s o l i n e
B l e n d i n g U n i t 270 a n d t h e h e a v y p o l y g a s o l i n e is pumped
(257-G-04) t o H y d r o g e n a t i o n U n i t 2 5 9 .

-122-
4.4.16 H.F. A l k y l a t i o n U n i t 2 5 8 (ZO-GEM-6982)

P u r p o s e of t h e Unit is t o i n c r e a s e t h e g a s o l i n e y i e l d
by t h e c a t a l y t i c a l k y l a t i o n of i s o - b u t a n e a n d u n p o l y m e r i z e d
C3 a n d C4 o l e f i n s .
T e c h n o l o g y Used

See P a r a g r a p h 3 . 4 . 1 9 .

Process D e s c r i p t i o n

E x c e p t f o r a n a d d i t i o n a l i s o - b u t a n e - r i c h f e e d stream,
i d e n t i c a l t o H.F. A l k y l a t i o n U n i t 153. S e e P a r a g r a p h
3.4.19.

4.4.17 P o l y G a s o l i n e H y d r o g e n a t i o n U n i t 2 5 9 (ZO-GEM-6983)

Purpose o f t h e U n i t is t o s a t u r a t e t h e o l e f i n s i n t h e
heavy cat p o l y g a s o l i n e .

T h e o l e f i n t a r g e t c o n c e n t r a t i o n f o r t h e 10 RVP g a s o l i n e
p r o d u c t i s 20 v o l . % maximum. To meet t h i s s p e c i f i c a t i o n ,
t h e p o l y g a s o l i n e is s p l i t and t h e heavy g a s o l i n e i s
hydrogenated. Preliminary gasoline blending i n d i c a t e d
t h a t t h e Cg a n d h i g h e r o l e f i n s s h o u l d b e h y d r o g e n a t e d a n d
t h e u n i t h a s been s i z e d a c c o r d i n g l y . F i n a l b l e n d i n g
r e s u l t s , h o w e v e r , show t h a t Cg o l e f i n h y d r o g e n a t i o n
i s n o t n e c e s s a r y . C o n s e q u e n t l y , U n i t 259 is s i z e d
conservatively.

T e c h n o l o g y Used

See P a r a g r a p h 3 . 4 . 1 7 .

Process D e s c r i p t i o n
The h e a v y c a t p o l y g a s o l i n e a f t e r m i x i n g w i t h t h e make-up/
r e c y c l e hydrogen is heated v i a t h e reactor e f f l u e n t i n
E x c h a n g e r 259-E-01 a n d b r o u g h t - u p t o t h e o p e r a t i n g
t e m p e r a t u r e by Heater 259-B-01. Reactor 259-D-01 u s e s
multi-beds w i t h hydrogen quench f o r t e m p e r a t u r e c o c t r o l .
The e f f l u e n t i s c o o l e d i n Coolers 259-E-02 a n d 0 3 , a n d
f l a s h e d i n D r u m 259-F-01. The o v e r h e a d is s p l i t i n t o
r e c y c l e a n d o f f g a s streams.

T h e bottoms l i q u i d f l o w s t o S t a b i l i z e r 259-D-02. After

c o o l i n g t h e s t a b i l i z e r o f f g a s e s a r e combined w i t h t h e
o f f g a s e s from F l a s h Drum 259-F-01 a n d s e n t t o H2 P u r i f i c a -
t i o n U n i t 2 6 1 . The c o o l e d s t a b i l i z e d h e a v y g a s o l i n e i s
s e n t t o G a s o l i n e Blending U n i t 270.

C a t a l y s t r e g e n e r a t i o n f a c i l i t i e s are provided.

-123-
4.4.18 L i g h t Ends R e c o v e r y U n i t 260 ( ZO-GEAI-6 9 8 0 )

Purpose of t h e U n i t is t o s e p a r a t e t h e l i g h t g a s o l i n e
and i s o - b u t a n e from t h e hydrocarbon-rich o f f g a s e s .

Process Description

O f f g a s streams f r o m C ' n i t s 2 5 4 , 2 5 5 a n d 256 a r e f i r s t

f l a s h e d i n D r u m 260-F-02. The o v e r h e a d v a p o r s a r e
c o m p r e s s e d (260-C-01) a n d t h e l i q u i d i s pumped
(260-G-01) t o t h e o p e r a t i n g p r e s s u r e o f D e e t h a n i z e r
260-D-01.

The l o w - p r e s s u r e o f f g a s f r o m U n i t 254 i s f i r s t c o m p r e s s e d
and t h e n f l a s h e d w i t h t h e o f f g a s from U n i t 261 i n D r u m
260-F-01. The drum l i q u i d i s c h a r g e d t o D e e t h a n i z e r
260-D-01.

The d e e t h a n i z e r o v e r h e a d is combined w i t h Drum 260-F-01

o v e r h e a d a n d S t a b i l i z e r 255-D-04 u n c o n d e n s e d gases a n d
s e n t t o t h e f u e l g a s h e a d e r . The f e e d t o D e b u t a n i z e r
260-D-02 i s t h e d e e t h a n i z e r b o t t o m s . In the debutanizer,
t h e a d d i t i o n a l i s o - b u t a n e f e e d f o r U n i t 258 i s f r a c t i o n a t e d
f r o m t h e light gasoline which is sent to Gasoline
B l e n d i n g U n i t 270.

4.4.19 H 2 P u r i f i c a t i o n U n i t 2 6 1 (ZO-GEM-6984)

Purpose of t h e Unit i s t o o b t a i n from t h e hydrogen-rich

o f f g a s e s a h y d r o g e n make-up stream of 90% p u r i t y .

T e c h n o l o g y Used

Commercial c r y o g e n i c t e c h n o l o g y , s u c h as o f f e r e d by
L i n d e D i v . o f Union C a r b i d e C o r p . , i s u s e d .

Process Description

Two of t h e t h r e e f e e d streams r e q u i r e c o m p r e s s i n g
(261-C-01 a n d 0 2 ) b e f o r e c h a r g i n g t o t h e s y s t e m . The
combined f e e d i s f i r s t c o o l e d i n C o o l e r 261-E-01 by t h e
+3Z°F r e f r i g e r e n t f r o m R e f r i g e r a t i o n U n i t 2 4 1 a n d
f l a s h e d i n D r u m 261-F-01 f o r h e a v y h y d r o c a r b o n a n d water
removal. The g a s e s t h e n p a s s t h r o u g h t h e M o l s i e v e
S e c t i o n 261-D-01 f o r f i n a l d r y i n g a n d C02 r e m o v a l . In
Cold Box S e c t i o n 261-D-02, t h e make-up h y d r o g e n i s
recovered and s e n t t o U n i t 211 f o r f i n a l compression.
The c o l d b o x h y d r o c a r b o n g a s e s a r e c o m p r e s s e d i n
C o m p r e s s o r 261-C-03 a n d mixed w i t h t h e l i q u i d s s e p a r a t e d
i n F l a s h D r u m 261-F-01. The r e s u l t a n t m i x t u r e i s a
feed f o r L i g h t E n d s R e c o v e r y U n i t 2 6 0 .

-124-
4.4.20 Alcohol R e c o v e r y U n i t 262 (ZO-GEM-6985)

P u r p o s e of t h e U n i t i s t o p r e p a r e a m a r k e t a b l e a l c o h o l
3 m i x t u r e p r o d u c t a n d t o r e c o v e r m e t h a n o l f o r make-up
t o R e c t i s o l U n i t 205.

T e c h n o l o z v Used

B e c a u s e of t h e l i m i t e d a l c o h o l i n f o r m a t i o n a v a i l a b l e t o
MRDC, t h e d e s i g n of t h i s u n i t i s g e n e r a l i n n a t u r e .
D i s t i l l a t i o n is used t o s e p a r a t e t h e b u l k of t h e water
a n d a c i d s from t h e r a w a l c o h o l s . Methanol is t h e n
f r a c t i o n a t e d from t h e a l c o h o l m i x t u r e . A benzene
a z e o t r o p i c s y s t e m i s u s e d f o r f i n a l water r e m o v a l . The
f i n a l s t e p i s t h e h y d r o g e n a t i o n of t h e a l d e h y d e s a n d
k e t o n e s t o improve t h e m a r k e t i n g v a l u e of t h e a l c o h o l
mixture.
Process Description

The a l c o h o l / a c i d water m i x t u r e f r o m F-T S y n t h e s i s U n i t 250

f l o w s t o F r a c t i o n a t o r 262-D-01 i n w h i c h t h e a l c o h o l s
a r e d i s t i l l e d from t h e a c i d i c w a t e r . B e c a u s e a l c o h o l -
w a t e r a z e o t r o p i c m i x t u r e s o c c u r , a p o r t i o n of t h e water
d i s t i l l s o v e r h e a d w i t h t h e a l c o h o l s . The a l c o h o l s ,
t o g e t h e r w i t h a h e a v y a l c o h o l r e c y c l e stream f r o m
M e t h a n o l Tower 262-D-03, a r e n e x t c h a r g e d t o A l c o h o l
S p l i t t e r Tower 262-D-02 f r o m w h i c h a c r u d e m e t h a n o l o v e r -
h e a d p r o d u c t i s o b t a i n e d . The c r u d e methanol. i s r e d i s t i l l e d
i n t h e m e t h a n o l t o w e r t o o b t a i n a n a c c e p t a b l e make-up
m a t e r i a l f o r G a s P u r i f i c a t i o n . U n i t 2 0 5 . The h i g h e r
b o i l i n g a l c o h o l s (bottoms) are r e t u r n e d t o t h e a l c o h o l
s p l i t t e r tower.

The bottoms stream f r o m Alcohol S p l i t t e r Tower 262-D-02

i s f e d t o Heavy A l c o h o l Tower 262-D-04 i n t o w h i c h b e n z e n e
is added t o r e m o v e , v i a t h e b e n z e n e - w a t e r a z e o t r o p e , t h e
r e m a i n i n g water. The a z e o t r o p i c o v e r h e a d i s pumped t o
Tower 262-D-05, w h e r e 50 p s i g steam i s u s e d t o s t r i p t h e
b e n z e n e w h i c h i s t h e n r e t u r n e d t o Tower 262-D-04.

The a l c o h o l bottoms stream f r o m Alcohol Tower 262-D-04

is pumped t o H y d r o g e n a t i o n S e c t i o n 262-D-06 w h e r e t h e
a l d e h y d e a n d k e t o n e i m p u r i t i e s are h y d r o g e n a t e d t o t h e i r
corresponding alcohols. Make-up h y d r o g e n i s s u p p l i e d
from H2 R e c o v e r y U n i t 2 1 1 a n d t h e p u r g e g a s i s r e t u r n e d
t o t h e same u n i t . A small p o r t i o n of t h e u p g r a d e d a l c o h o l
mixture i s s e n t t o Hydrocarbon Recovery U n i t 210 f o r t h e
p r e v e n t i o n of i c e f o r m a t i o n d u r i n g t h e c o l d h y d r o c a r b o n
washing o p e r a t i o n .

-125-
 ,

The waste water streams from Towers 262-D-01 and 05

are pumped (262-G-02 and 09) after cooling (262-E-13)
to Waste Water Treatment Unit 2 3 5 .
4.4.21 Unit Capacity Summary
The capacities of the principal process units are
summarized below in conventional flow rates:
--Capacity, Unit/SD--
Unit N o . Name Input output

201 Gasification 2 2 . 8 MT coal 1 , 7 5 5 MMSCF

202 Raw Gas Shift 3 3 1 MMSCF -
205 Gas Purification 1 , 0 6 2 hlMSCF 742 MMSCF
210 Hydrocarbon
Recovery 277 MMSCF 235 MMSCF
250 F-T Synthesis 742 MMSCF 1 8 . 1 MBbl
251 Naphtha E-iydro-
treating 1 . 3 MBbl
253 3'-T Prod. Hydro-
treating 1 1 . 4 MBbl -
255 Catalytic Reforming 4 . 3 MBbl -
256 c5/c(j Isomerization 4.0 MBbl -
257 Polymerization 6.5 MBbl -
258 Alky 1at ion 2 . 4 MBbl ( 5 5 0 Bbl/SD alkylate)
259 Poly Gaso. Hydro-
genat ion 1 . 2 MBbl -
260 Light Ends Recovery 1 . 0 MBbl -
261 H2 Purification 8 MMSCF 6 MMSCF
262 Alcohol Recovery 510 Mlb -
SNG Train 235 MMSCF 1 7 3 MMSCF

-126-
 + 7969.9 + 1592.8 -68 18.3 - 2.5 Mlbslhr
Stack Gas Nitrogen Air
to Atmosphere Air ( o n l y 02 balancedl
to Atmosphere

GPM ld195'Ft
1 Gosilication Area
Mined
-2308.2
I Lurai Pressure Gasiticat:onl Coal
Methanol - 0.3

Sluice Venl + 25.5

Ash + 147.4

+ 8.6.

Waste Air
(not balancedl + 15
Sulphur
PmdUCt + 5.1
Catalyst
losses + 31
Catalyst
Make UP - 76
Spent
Catalyst + 25
Heavy Alcohol
Product
+ 21 2

+ 526.6
Blow D o i n Water
t o Holding Pond +
+ 3779.3
vaporation Losses
to Atmosvhere @-
CO, Furgo Gas
01
* to Almosphere +
Waste Air
(not b a l a n c e d l
+ 10.3

-4374.9
Fresh WaIer
+-- Distillolo Fuel Oil
Producl
Heavy Fuel 011
Product +
25 L
7.4

I ?

+ 10.0
Doaemtor Losses
l o Atmosphere +
1I The steamlBFW circuit 01 Ihe complex 15 shown
simplified as i t I S descnbed ~n detal1 withln the
separate steom/BFW balance 2 0 - G E M - 6 9 8 6

21 In Case I1 the Coal Handling Unit is somewhat

larger than in Case I , because line coal rate
to boiler (stream 21 IS increased but wellsized
coal to Gasification Area 1s the same

I--'--'--'
7'--1'-'-' 1't"
Waste Steam #UT* Lc. Propane LPG
Electric SNG Gasoline Pfomcf Product
t o Atmosphere
Power Product Product
Excess
Mlbslhr + 601MWb) t 2.3 + 315.1 + 1LO.9 + 1.2 + 8.2

-127-
 <

Y
0
0
/ N

0
VI
A

I S I I

1 I
L
L J 1
- A

J 0: 0
U

0
W

<

a
 \

F R W HC
UNI'
7
ICOVERY
110
7
.
UNIT 211 1
I
.
UNIT 251
STAU
TO
UNI
t
1
AS;

!22
I
NAP
.ER7 FROM
UNI'
c
A
i PURIFICATION
I5

<) c
EOUIPMENT IN BOX
SUPPLE0 BY COMPRESSOR VENDOR '251-GOl

4
RECOMPRESYONGAS
1 099 02
251-C-01
p\

t
OFF
TO BO1
UNIT
i

TO METHANATION
I I
UNIT 212

, I 251-B-Ol/
I 251-0-02
-

I 51-E-03
*
w I
251-€-OS

251-DO3
251-E-06

u251-F-03
251-G-03
1
1
1
1
1
. 0
. 0

1 . 0
I . 0
. 0
. v
. 0

21 1-0-01
2 11- c-02

3- t-JLO1
251-G-02

A
TO G A S IE
251-E-07 BLEl IG
70

251-G-0 4 )
W R
R
IT NOTES
I5 S ~ ? C A M L . N I T H O U T S i i l E A h NUMBERS
211-c-01 ARE NOT INCLUDED IN THE OVERALL
M d l E d l A L BALANCE

I
>

FROM UNIT 271 FROM UNIT 262 FRol UNIT 256 FROM UNIT I
1 TO UNIT 253 TO UNIT 256 FUEL GAS TO UNIT 262 TO UNIT 271

-129-
i
 ?
N
I
rn
0
w

Y
N
I
rn
I
p.
0

N
I 2
N
P P I
rn
I
Y 0
I
N ul
?
9

< >

b
I SCL llNn
Y l I lNYW3I V
1Y51
I I 01
CLZ l l N n M31W
4
1
10-9 - 7lZ 10-0 -ELZ
f--
LO - 3 -7LZ
zo-a - E t z
A
-
Y
LO - 3 - ELZ'
zo-0 EtZ
-
zo- 3 -ELL
'0-3-7te$
: 0 SO-3-CLZ
D--
70 -3-EtZ LO-3-ELZ
EO-3-EtZ
to-a EO - 3 - ELZ

F to-a -Etz
t Y
LO-3-az
L
LO -3 -ELZ
zo -3 - ELZ n--J
Y
b

II T U UNn
ONIAMO ON5 01

T
20-3 -CLZ LO- 3- fLZ
 BFW BFW
200 PYG STEAM L P STEAM FROM I IT 231 TO UI
.A 7 1

m 250-0-01 ITEU NO. NkUE

EQUIPYENT LIST

OPER.
+SPARE
APPROX
I 0 LENGTH
.:T

I
p50-C-01 SYNGAS i RECYCLE COUPRESSOR 3+0
10'-E" 100'
18'4'' 50'
250-F-02 20'-0"
12'"''
50'
35'
250-D-03 50-E-01 P-T PEED/EFILUENT SIDE
STREAU H.E. I+O
250-E- 150-E-02 P-T .*WE HEAT
F-T PSlC
200 WASTE STEAM
H U T I GENERATOR
BPI E E 1+0
\ Il + O
F-T VlSTE HEAT CONDENSER
F-T WASTE HEAT TRlY CONDENSER l+O
F-T BF1 TRIU HEATER 1+0

1
50 PSIC
F-T WASTESTEAI
HEAT GENERATOR
250- E-03 250-E-0 5 It0
F-T WASTE IILAT
20 PSIG STEAM GENERATOR 1+0

250-F-01 COWRESSOR SUCTIONAL DRrm 3+0

250-G-04 250-F-02 HOT OIL SURGE DRUM 1+0

250-G-01 3rl
1+2
250-G-02
250-G-03
?+I
250-G-04 1+1

4 .03
I

LIGHT OIL

BL 730 UNIT 252

FROM WASTE WATER

TREATMENT
UNIT 2 3 5

PRESSURE PSlG
0 TEMPERATURE F

I WATFR
F l a w R*TE DRY GAS

F l a w RATE STEAM
,bm"i,hr,

Ulbslhr
POLYMERIZATION A W LIQUTDS
UNIT 257
<

250-E-07
) 250-C-01 250- E-OB NOTES
STREAMS WITHOUT STREAM NUMBERS
ARE NOT INCLUOED IN THE OVERALL
MATERIAL BALANCE
SYflGAS
FROM GAS
PURIFICATION
UNIT 205

1
I
I
250-F-01 L 4
UNIT 252

LF N 200 BFW
-132-
 i
U G H 1 GAS LIGHT GAS
TO COI REMOVAL lU FUEL GAS
UNIT 213

132 91

Q Q

UNIT 250
6
252-G-OL
252-E-OL
7 252- G-05
a 2 52- E- 06

252-E-10
252-E-09 A,

FROM HC RECOVERY
UNIT 210

:e
252- F- 03

t F-
- 05
252-D-02
252-E-07

CAT POLY F
TO CATAL
POLYHEHIZA

252-E-08
252-608
0
252-D-03 A

252-8-02

h
252-E-12
252-GI5 (
252-G-09
'mI
A

252-E-11
- - 252- D-OL
I 4
UNIT 153

HEAVY aL
FROM F - T SYNTHESIS
252-8-03 I
UNIT 250
252-G- 12
4 A i

1 252-G-03
&qJ 252-G-13
4
" VACUUM RESIDUE
TO BOILER
UNIT 222
NOTES
STREAMS WITHOUT STREAM NUMBERS

ARE HOT INCLUDED IN T H E OVERALL

H M E R I A L BALANCE

+ 266 LQ

FUEL GAS AIR

3627 3j7

-133- H
UMT 252
FRACTIONATION
 4 H2 MAKE UP TO PC SOLINE STACl %S TO L
IATlON FROM H2 RECOVERY HYDR \TION ER ENDS RE -RY
52 UNIT 211 U 9 222 UNIT

487.79

c
'B >

!51-E-01
4

251-F-01

1
~ & WATER
TO WMTE; AW
TREATMENT
UNIT 2 3 5 ITEM NO. NlYE
EQUIPMENT LIST
OPER.
+SPIRE
APPROX.
I.".LENGTH T-T
253-8-01 HYDROTREATER FEED HEATER 1 + 0

253-F-02 253-C-01 HYDROTREATER RECYCLE COMPRESSOR 1 + 0

253-0-01 HYDROTREATER REACTOR 1 + 0 6'-0" 30'

I t 0
1 +
+ G0
1 t
1 1 0
o

HIGH TEMP FLASH DRUH

W X TEYP FLASK
HYDROTREATER DRUMPUMP
PELI)

TO LIGHT
EYDRUCREATER FEED PBYP
253-E-01 !51- D-01 !51-G-02 251-E-08
ENDS RECOVERY .
.
.
...
.
..
..
.
..
.
..
.
..
..
..
.
.
..
..
.
..
.
..
..
.
..
.
..
.
..
..
..
.
.
..
..
..
.
.
...
.
..
.
..
..
UNIT 2 6 0
I f M A I N FRACTIONATOR FEED HEATER

( U A l N FRACTIONATOR 1 + 0 91.6" 58'

I r
+l 251-E-09
DISTILLATE FUEL OIL STRIPPER
DEBUTilNIZER

NAPHTHA SPLITTEA
1 + 0
1 + 0
1 + 0

1 + 0

1 + 0
41-6''
6'-6"
2'-6"
80'
71'
20'

253-D-01 , l + O
1 + 0

J
, + a
1 + 00
1 + 0
1 +
+ 00
253- 8-01
I1 r+ a0

251-E-01 4- 1
1
+ o
+ o
M A I N FRACTIONATOR REFLUX DRUM 1 + 0
OEBUTANIZER REFLUX DRUM I1 +1 O0
DISTILLATE FUEL OIL NAPHTHA SPLITTER REFLUX DRUM
PRODUCT

I * 254-6-01
254-G-02
254-6.03
254-G-04
MAIN FRACTIONATOR REFLUX PUUP
OEBUTANIZER FEED PUMP
DFO PRODUCT punp
HFO PRODUCT PUUP
1 +
I t 1
1 + 1
I + ,
L I

I
25 L-E-06 PUMP PUUP
1 + 1

4 254-G-05
254-G-06
254-G-01
NAPHTHA SPLITTER
DEBUTANIZER REFLUXREFLUX
NAPHTHA SPLITTER OVHD PRODUCT
.D,I"D
1 + 1
. .
1 * 1

HEAVY FUEL OIL 1254-G-08 NAPHTHA SPLITTER m H S PUMP l r l 1 1

m P R 0 DUCT 254-G-09 WASTE WATER PUMP l + i

!51-D-0 3 I1 L
%

.i
/<is?
251-E-07 /-r r\
Q f 5)
251-G-05 "(EA""FLLL O L
TOUNIT213

L A To C5ICs
ISOMERIZATION
UNIT 2 5 6

6K
251-E -10
NOTES
STREAMS WITHOUT STREAM NUMBERS
ARE NOT INCLUDED IN THE OVERALL
MATERIAL BALANCE

) ) TO CATALYTIC
REFORMING

& 1120

I,
21
UNIT 255

AIR W, 3 \M

I
TO WAS NATER
TREl :NT
UN 35 -134-
 1
m
M
r-l
I
 PENTANE ISOMERA STACK GAS H r RI8 . GAS
TO GASOLINE BLENl TO BOILER TO H VERY
UNIT : UNIT 2 2 2 I 1

256-G-0?
TO LIGHT ENDS RECOVERY

1 UNIT 2 6 0
EQUIPMENT LIST

II
b 'EM NO. NAME OPER. APPROX.
+SPARE 1.D. LENGTH T-'
256-E- 02 6-8-01
I
256-D-03

.
6-C-01
256-E- 01 I 6-0-01 DEISOPENT&NIZER
ISOMERIZATION REACTOR
1 + 0
1 + 0
81-01,

91.0"
6-0-03
6-D-02
STABILIZER 1 + 0 4,-0,,
6-0-04 DEPENTANIZER 1 + 0 5'.W

6-E-01 DEISOPENTANIZER O V W CONDENSER i + 0

6-E-02 OEISOPENTANIZEA OVW TRIM
CONDENSER 1 + 0
6-E-03 DEISOPENTANIZER REBOILER 1 + 0
256-E-10 6-E-04 ISOMERIZATION REACTOR FEED,
EFFLUENT
ISOMERIZATION
H E. REACTOR EFFLUENT 1 + 0
6-E-05
CWLER 1 r o
256- F- 0 L 6-E-06 ISOMERIZATION REACTOR EFFLUENT
TRIM C M L E R 1 + 0
6-E-07 STABILIZER FEED/BOTTOYS H.E. 1 + 0
5-E-08 STABILIZER OVHD CONDENSER 1 + 0
5-E-10
6-E-09 STABILIZER O V W TRIM CONDENSER 1 + 0
- A
S.E.,,
5-E-13
STABILIZER REBOILER
DEPENTANIZER O V W CONDENSER
1
I
+ 0
+ 0
DEPENTANIZER REBOILER 1 + 0
DEPENTANIZER B O T m M S C M L E R 1 + 0
256-G-OL I 256-G-03 5-E-14
5-E-15
DEPENT~NIZERB o r n u s T R ~ YCWLERI + o

5-F-01
i- 72
3-F-02
3-F-03
5-F-04
!56-E-07 I 156-D-OL

p
5-G-01

3-G-02 STABILIZER REFLUX PUMP I t 1

3-G-04
5-G-03 DEPENTAN:ZER REFLUX PUMP 1 + 1
PENTANE RECYCLE PUMP 1 + 1
i-c-0s
i-G-05 REACTOR FEED PUMP 1 + 1
HEXANE ISOMERATE PUMP l + l

256-E -1 3

- -
@) 256-G-06
I 0 STREAM NUMBER

0 PRESSURE PSlG

4 0 FLOW RATE DRY GAS

F

lbmolihr
TO GASOLINE
HEXANE ISOMERATE
BLENDING
- 256-E-1 5 FLOW RATE STEAM

12
UNIT 270
< AND LIQUIDS
UlbPihr

256-G-05
256-C-01

NOTES.
STREAMS WITHOUT STREAM NUMBERS
MATERIAL
ARE NOT INCLUDED
B A L A N C E .I N THE OVERALL

E!& 4 a ..La '

FUEL GAS AIR HZ M . UP

FROM H, :OVERY
UN 11
 012 llNn
3N 3Nll05V0
l l O S V 0 AlOd
WOU318 01
lV3 lH011
1
F qq c
c
33NVlVE lVlU31VW
l l V M 3 A O 3 H I NI 0 3 0 n 1 3 N I I O N 3MV
SM38clnW W V ~ Y I S i n o n i i M S W V ~ U I S
5310N
EO-9-LSZ c ' I 90-3-LSZ
1
90-9-LSt
OLZ 7O - J - L S Z r
Q
3NIa d 3N1'10SV9 01
31V'
1
A 1
LO-3-LSZ Iyc----, 11
0 . 1
n. I
0 . I
0 . 1
0 .. 11 30VM
n . 1
u . 1
0 . 1
0 . 1
0 . 1
&
OIL
ONlOl
@3N1
1
OL -3-esz
E 1-3-892 to-wsz d eo-3-ffiz
=VU
on' EO-0-9SZ
m zo-9-esz
L - - F lzJ 1-3-esz
c
7
SEi
IN3WlV3Yl
WOMj
I
 STACK GAS H2 c IGE FF GAS
TO UNIT 222 FROM IT 253
261
4
P
>
< >

259- B-01

EPUIPUENT L l S T
PEY NO NAME OPER.
+SPARE I D. LFYGTH T-T
APPROX

FEED HEdTER I + "

I RECYCLE COUPRESSOR I * I

IIYORffiENATION REACrnR 1 + 0 3'-6' 30'

STABILIZER i * o 3'-6' 70

-
. .

I
STABILIZER norrois CrnLE" I t 0
STABILIZER BOTTOUS TRIU CWLER I + 0

HYDROGLIATlON EFFLUEVT FLASli

DRUU I t 0
259- E-01 PEED PUMP REFLUX ORUU
STABILIZER 1 + 0
, * ,
259-E-02 STABILIZER REFLUX PUMP , + I
STAnlLlZER REBOILER PUVP I * 1

2 59- E- 01 ' 259- F- 01 2 59- E- 05

) 259-F-02
259-G-02
3-
259- D- 02

259 - G- 01 I 259-E-07
h
t 4 NOTES
nvy CAT POLY GASOLINE STREAMS WITHOUT STREAM N U M R E 9 S
259-E-08 T O GASOLINE BLENDING ARE NOT INCLUDED I N THE OVERALL
UNIT 270 MATERIAL BALANCE

HYDROGENATION
-138- UNIT 259

I
I
6SZ llNn W(1j 9SL l l N n W O W SSZ l l N n W O W
-6€1- S3SW ONINIVlN03 z H
531ON
20-3-t9Z
-g -@-
1033H
I 1llf)ll 01
LO-3-\92
10-3-L9Z b-
zo-a -19z to-a-igz
N01133S N01133S
20 -3 -192
3h31SlOW
20-3-191
m I
EO-3-1 92
< >
11 INn I N 01
M13AOC w 01 '03
i3n Id zH
 (3 262- F-

151
METHANOL

(7 4
TO GAS PURlFKaTlON
UNIT 205
262-F-01
c EQUIPUENT L I S T
oper APP'OX.

?
262-G-03 262-G-01 +Spare I D . Length T
262-G-01
262-0-02 262-D-0, ACID WATER FRACTIONATOR 1 + 0 12,-0.. 140,
262-0-02 METHANOL mwm
ALCOHOL SPLITTER I1 *t 0
0 21-61,
3'.0', 7
933 ''
262-0.03

v
h
1 !52-0-04
162-0.05

162-E-01
HVY ALCOHOLS mwm
ALCOHOL RECOVERY STEAM STRIPPER 1 +

ACID WATER F R A C T I O N A m R REBOrl LER

1 *

110
I)
o
151.0"
51.0'.
77,
72

162-E-02 ACID WATER FRACTIONAmR Ovm

262-0-01 162-E-03
CONDENSER 1 + 0
ACID WATER FRACTIONATOR OVHD
I TRIM CONDENSER l + O

a !6Z-E-O4 ALCOHOL SPLITTER REBOILER 1'0

3
262- E-07 262-F- !62-E-05 ALCOHOL SPLITTER OVHD
CONDENSER I t 0
!62-8-06 ALCOHOL S P L l T T E R OYHD TRIM
ALCOHOL WATER MIXTURE 262-D-05 CONDENSER 1 t "
FROM F - T SYNTHESIS !62-E-07 METHANOL TOWER REBOILER i + o
1

rl
UNIT 250 !62-E-08 METHANOL mim ovm C O ~ E N S E R 1 1 0
'62-E-09 METHANOL TRIM COOLER
lI +t O0
262-E-OL '62-E-IO
'62-E-1,
XVY ALCOHOLS TOWER REBOILER
W Y ALCOHOLS TOWER OYHD
CONDENSER
./ 62-E-12 I N Y ALCOHOL TOYER BTMS COOLER
1 + 0
1 + 0
2 .G-06 2625-07 62-E-13 ACID WATER COJLER 1 ' 0

L!f
62-F-0,
262-D-OL STEAM
62-r-02
I 62-I-04
62-1-03

@E$
262- E-01
I ~
62-G-0,

62-0-02
62-6-04
62-G-03
62-c.-05
...
WATER
ALCOHOL
ACID S P L PUMP
I T T E R REFLUX PUUP
METHANOL TOWER FEED PUHP
WETHANOL TOWER RKFLUXjPROOUCT
PUUP
1 t+ 1
1 t 1

1 + 1
1

f
52-G-0,
62-G-06 W Y ALCOHOL mwm REFLUX PUMP 1 + 1
STEAM S T R I P P E R FEED PUUP 1 + 1
262-G-02 62-6-08 ALCOHOL HYDRmENATION FEED PUMP i + i
62-G-09 STEAU COmEXSATE, PUMP 1 + 1

I
262- E-10

P
ALCCHOL M I X T Z
0 STREAM NUMBER

$
TO UNIT 210
262-G-08 P'IESSIIRE PSI(.
2 ~

0
a
TEMPERATURF
FLOW RATE DRY GAS
OF

~ b ~ ~ l / h
262-D-06 FLOW RATE STE911
WlbSIhr
HYDRl !
4 < L'qurDs
ALCOHOL
T O STORAGE
MIXTURE

4
HYOROGEN PURGE
TO HYDROGEN RECOVERY
UNIT 211
NOTES:
STREAMS WITHOUT STREAM NUMBERS
ARE NOT INCLUDE0 I N THE OVERALL
MATERIAL BALANCE

i
i
..j
&0812

.i
/
"2 I
FROM UNjT 211
I

-140- I

1
I
 BASE CASE I 1
4 . 5 OFFSITE UNITS

1 Majority of the offsite units in Base Case I 1 are very similar

those in Base Case I. Consequently, descriptions are not
w e p e a t e d ; differences, principally capacities, are discussed
below.
Unless stated otherwise, units are shown on Block Flow Diagram
ZO-GEM-6988 in Sub-section 4 . 4 . In addition, units such as
boilers, generators and water treaters are also included in
Steam/BFW Balance ZO-GEM-6986 located in Sub-section 4 . 6 .
4.5.1 Oxygen Production Unit 221
Identical to Unit 121.
4.5.2 Boiler Unit 222
Differences are as follows:
Main
- - -Fuel
--
Fine coal quantity (composition listed in
Sub-section 2 . 3 ) 4 0 6 . 9 0 Mlb/hr
- ---- -
SuEplementary - -
Fuels
/ - Oil quantity (from Gas Liquor Separation
Unit 2 0 7 ) 4 6 . 4 9 Mlb/hr
- Vacuum tower residue (from Fractionation
Unit 2 5 2 )
Quantity 2.0 Mlb/hr
Low heating value 17,750 Btu/lb

-Incinerat
- - _ _ - ion
- _ _Fuel
Sour offgases (mainly from Sulfur Recovery
Unit 206)
Quantity 1-,
826.5 Mlb/hr
Low heating value 243 Btu/lb
NOTE: The heat content of these gases (30 Btu/SCF) has n o t
been included in the boiler thermal balance.
Normal Capacity 3 , 1 1 1 . 3 Mlb/hr

4.5.3 Main SuDerheater Unit 223

Capacity is changed as follows:
Normal CaDacitv 3 , 1 1 1 . 3 Mlb/hr

4.5.4 Superheater Unit 224

Duties are as follows:
200 psig Steam 100 psig Steam
Inlet pressure, psig 200 100
Outlet pressure, psig 185 85

-141-

I
 2 0 0 psig S t e a m 100 p s i g S t e a m
I n l e t t e m p e r a t u r e , OF 387 338
Outlet temperature, OF 586 469

F u e l c o n s i s t s of a p o r t i o n of t h e o i l r e c o v e r e d f r o m G a s
Liquor S e p a r a t o r Unit 107:

O i l quantity 5.22 Mlb/hr

Normal Capacity

C o i l 1: 200 p s i g steam s u p e r h e a t i n g 78.7 M l b / h r

C o i l 2: 100 p s i g steam s u p e r h e a t i n g 777.1 M l b / h r

4.5.5 E l e c t r o s t a t i c S t a c k G a s P r e c i p i t a t o r Gni.t 2 2 5
N o r m a l Capacity 2 1 6 . 5 Mlb-mol/hr

4.5.6 S t a c k G a s C l e a n - u p U n i t 226

Normal C a p a c i t y 2 1 6 . 5 Mlb-mol/hr containing

4 8 . 1 lb-mol/hr SO2

4.5.7 I n s t r u m e n t a n d P l a n t A i r U n i t 2 2 7 ( n o t shown)
I d e n t i c a l t o U n i t 127 (Estimated instrument a i r
r e q u i r e m e n t f o r t h e t o t a l complex i s 750 l b - m o l / h r ;
see P a r a g r a p h 3 . 5 . 7 . )

4.5.8 C o a l H a n d l i n g U n i t 228 ( S e e SFD ZO-GEM-6909, Sub-section 3 . 5 . )

Gasifier well-sized coal production is i d e n t i c a l t o

Base Case I . Because o f t h e h i g h e r e n e r g y r e q u i r e m e n t s
i n B a s e C a s e 11, t h e q u a n t i t y of b o i l e r f e e d coal is
i n c r e a s e d t o 406.9 Mlb/hr.

4.5.9 Ash H a n d l i n g U n i t 229 ( S e e SFD ZO-GEM-6911, Sub-Section 3 . 5 . )

Identical t o Unit 129

4.5.10 BFW P r e p a r a t i o n U n i t 2 3 1

N o r m a l Capacity
Temp., OF Flow, Mlb/hr
MP c o n d e n s a t e 479 346.6
LP c o n d e n s a t e 297 1,628.5
Vacuum c o n d e n s a t e 173* 2,190.7
M e t h a n a t i o n U n i t 212 p r o c e s s
condensate 288 110.8
BFW make-up water -
173* 2,090.4
Total 221 6,367.0
* A f t e r h e a t i n g i n 250-E-03.
-142-
 -Demineralizer
------_- -
(2311_2)

Normal C a p a c i t y 2 , 0 9 0 . 4 Mlb/hr
(14). 5 . 1 1 Cooling. Water Make-UD P r e D a r a t i o n U n i t 232

Normal C a p a c i t y

Mlb/hr

T r e a t e d f r e s h water 2,284.5
T r e a t e d water from U n i t 235
a n d h u m i d i t y from U n i t 2 2 1 1,961.9
Total 4,246.4

4.5.12 C o o l i n g Water Tower U n i t 233

Normal C a D a c i t v

GPM
-
Steam t u r b i n e c o n d e n s e r d u t y 174,300
Trim c o o l e r duty . 109,590
Total 283,890

4.5.13 E l e c t r i c Power G e n e r a t i o n U n i t 234

Description

G e n e r a t o r 234-M-01 u s e s 48 p s i g , 3780F steam w i t h

C o n d e n s i n g T u r b i n e 234-T-01. Back P r e s s u r e T u r b i n e
234-T-02 of G e n e r a t o r 234-M-02 i s f e d w i t h two
superheated streams:

185 p s i g steam: 78.7 hllb/hr

85 p s i g s t e a m : 777.1
Total 855.8

N o r m a l Capacity
Steam Flow,
blw Mlb/hr

234-M-01 46.9 955.4

234-M-02 8.9 855.8

4.5.14 Waste Water T r e a t m e n t U n i t 235

N o r m a l Capacity

Composition Flow, M l b / h r
O r g a n i c a c i d s and p h e n o l s 8.9
Ammonia 1.3
Water c o n t a i n i n g some H2S 2,093.4
Total 2,103.6
-143-
4.5.15 F l a r e a n d Blowdown F a c i l i t i e s 236 ( n o t shown)

Normal C a p a c i t y

Blowdown water t o h o l d i n g pond 526.6 M l b / h r

4.5.16 S t o r a g e 237 ( n o t shown)

The f o l l o w i n g i s a summary o f t h e p r o d u c t , i n t e r m e d i a t e
and c h e m i c a l s t o r a g e t a n k c a p a c i t i e s w h i c h a r e n o t
located within the process o f f s i t e units:

P r o d u c t S t o r a g e (15 d a y s )

Anhydrous ammonia 1,700 ton (refrigerated)

Sulfur 1,000 t o n (covered)
Gasoline 2 2 4 , 0 0 0 Bbl (floating roof)
Diesel f u e l 3 8 , 0 0 0 Bbl (cone r o o f )
Heavy f u e l o i l 11,000 Bbl (cone r o o f )
P r o p a n e LPG 18,500 Bbl (pressure)
B u t a n e LPG 2 , 4 0 0 Bbl (pressure)
Alcohols 3 4 , 0 0 0 Bbl (floating roof)
Intermediate Storage
Hydrotreater U n i t 251 f e e d
(15 days) 2 2 , 0 0 0 Bbl ( f l o a t i n g r o o f )
H y d r o t r e a t e r U n i t 253 f e e d
(15 days) 1 8 8 , 0 0 0 Bbl ( f l o a t i n g r o o f )
R e f o r m e r U n i t 255 f e e d
( 5 days) 24,000 B b l ( f l o a t i n g r o o f )
P o l y m e r i z a t i o n U n i t 257
feed (2 days) 1 4 , 0 0 0 Bbl ( p r e s s u r e )
Chemical S t o r a g e

D i i s o p r o p y l ether 1,500 B b l
Methanol 1,000 Bbl

4.5.17 I n t e r c o n n e c t i n g Pipeway 238 ( n o t shown)

R e q u i r e m e n t s a r e somewhat l a r g e r t h a n i n Base Case I

b e c a u s e o f t h e g r e a t e r number o f o n s i t e u n i t s n e e d e d
for F-T p r o d u c t u p g r a d i n g .

n
-144-
 4.5.18 Refrigeration Unit 241

I \
Normal Capacity
Duty, MMBtu/hr
Temperature Level + 32OF - 450F
Purification Unit 205
including ammonia storage 25.5 70.5
HC Recovery Unit 210 - 43.4
H2 Purification Unit 261 2.1 -
27.6 113.9

4.5.19 Gasoline Blending Unit 270

Except for additional blending steams, identical to
Unit 154.
4.5.20 F-T Catalyst Preparation Unit 271
Purpose of the Unit is to prepare from magnetite iron
ore (Fe3O4) a promoted, reduced iron catalyst for the
fluid-bed Fischer-Tropsch reactors.
Technology Used
The catalyst plant design is based on literature articles
describing: (a) the manufacture of iron ammonia
catalysts, (16), and (b) the Sasol catalyst plant (13).
An overall general design has only been developed.
Promotors used and dosages, concentrate specifications,
specific operating conditions, etc., are confidential
and, thus, unavailable. This unit has been added to the
offsites because of the quantity of fused catalyst
required and the problems of shipping the sensitive
catalyst under a H2 or inert gas atmosphere.
Process Description
Catalyst preparation consists of 3 steps: iron ore
purification, catalyst fusion and size reduction, and
catalyst reduction. Equipment contained in the iron ore
purification area includes:
- O r e unloading and storage
- Rotary drier for moisture removal before grinding
- Rod mill for size reduction required by air table
- Air separation table for tailings removal
- Concentrate storage

0 -145-

L
C o n c e n t r a t e y i e l d h a s b e e n assumed t o be 50 p e r c e n t .

Equipment i n t h e c a t a l y s t f u s i o n a n d s i z e r e d u c t i o n
s t e p includes:

- Electric resistance furnace for melting/intimate

m i x i n g of c o n c e n t r a t e a n d p r o m o t o r s
- Gyratory c r u s h e r and b a l l m i l l for size r e d u c t i o n
r e q u i r e d by t h e f l u i d - b e d r e a c t o r
- A i r s e p a r a t o r f o r e l i m i n a t i o n of f i n e s a n d o v e r s i z e
particles
- C a t a l y s t storage

Equipment r e q u i r e d i n c a t a l y s t r e d u c t i o n i n c l u d e s :

- F l u i d i z e d - b e d r e a c t o r f o r c o n t a c t of h y d r o g e n a n d
u n r e d u c e d F-T c a t a l y s t
- Hydrogen h e a t e r
- Heat e x c h a n g e r s f o r c o n d e n s i n g water p r o d u c t
- Hydrogen r e c y c l e compressor
- R e c y c l e gas d r i e r f o r m o i s t u r e c o n t r o l
- Reduced c a t a l y s t s t o r a g e u n d e r H2 o r i n e r t g a s
atmosphere

R e d u c t i o n t a k e s p l a c e u n d e r e l e v a t e d t e m p e r a t u r e and
pressure.

-146-
 BASE CASE XI
4.6 UTILITY REQUIREMENTS AND STEAM/BFW BALANCE

4.6.1 Utility Requirements

Utility requirements for the individual units can be found
as follows:
Utility Source
Fuel Type and stream number: BFD
ZO-GEM-6988 (Sub-section 4 . 4 )
Quantity and composition: Material
balance sheets (Appendix B)
Power BFD ZO-GEM-6988
Cooling water BFD ZO-GEM-6988
Boiler feed water Steam/BFW Balance ZO-GEM-6986
(Sub-section 4 . 6 ) i1
Steam Steam/BFW Balance ZO-GEM-6986
In addition, offsite Sub-section 4.5 contains utility
information.
~

I
4.6.2 Steam/BFW Balance
The steam and boiler feed water flows are shown on
Drawing ZO-GEM-6986. The steam/electric power balance
is acceptable in accordance with the study bases. Only
about 6 MW(e) is surplus in comparison with 257 MW of
total electric and steam power required in the plant
complex. In addition, all steam produced is utilized.

c
-147-
I
t
PI
0
N
-7
 BASE CASE I1
4.7 TRAIN PHILOSOPHY

e t r a i n p h i l o s o p h y f o r t h e v a r i o u s u n i t s w a s s e l e c t e d on t h e
b a s i s of p r o v i d i n g a p l a n t complex h a v i n g a n o n s t r e a m f a c t o r
of 92%. C o n s e q u e n t l y , p a r a l l e l t r a i n s h a v e b e e n u s e d f o r many
u n i t s t o g i v e f l e x i b i l i t y i n b o t h o p e r a t i o n and maintenance.
A l s o , b e c a u s e of t h e l a r g e s i z e o f t h e c o m p l e x , some u n i t s
must be d i v i d e d i n t o p a r a l l e l t r a i n s . In t h e h y d r o c a r b o n
p r o c e s s i n g a r e a , however, i n t e r m e d i a t e s t o r a g e is used t o p r o v i d e
this flexibility.

I n a d d i t i o n , a l l n o r m a l l y o p e r a t i n g pumps, r e c i p r o c a t i n g c o m p r e s s o r s
a n d c o n v e y o r s a r e p r o v i d e d w i t h a n 100% s p a r e .

S i n c e t h e same t r a i n p h i l o s o p h y i s u s e d f o r B a s e Case I 1 as i s
used i n Base Case I, o n l y t h e p h i l o s o p h y o f t h e new u n i t s i n
Base Case I1 a r e d i s c u s s e d b e l o w .
H y d r o c a r b o n R e c o v e r y U n i t 210

B e c a u s e of size l i m i t a t . i o n , t w o p a r a l l e l t r a i n s a r e p r o v i d e d .

F-T S y n t h e s i s U n i t 250

Using a c o n s e r v a t i v e scale-up factor o f 2 o v e r c u r r e n t commercial

f l u i d - b e d r e a c t o r s , f o u r r e a c t o r s are r e q u i r e d . In a d d i t i o n , a
spare r e a c t o r is p r o v i d e d f o r c a t a l y s t c h a n g i n g a n d m a i n t e n a n c e .
S i z e considerations a l s o r e q u i r e multiple towers, compressors,
a n d pumps; see e q u i p m e n t l i s t on PFD ZO-GEM-6977 i n S u b - s e c t i o n 4.4.

F-T P r o d u c t U p g r a d i n g U n i t s 252 Through 262

T h e s e u n i t s a r e s i n g l e t r a i n s a s e q u i p m e n t s i z e s a r e s m a l l enough
t o be s h o p f a b r i c a t e d . T h e o n l y e x c e p t i o n i s C a t a l y s t P o l y m e r i z a -
t i o n U n i t 257 w h i c h is p r o v i d e d w i t h two r e a c t o r s f o r o p e r a t i n g
flexibility .
To a c h i e v e o p e r a t i n g f l e x i b i l i t y i n t h e u p g r a d i n g a r e a , f e e d s t o c k
storage c a p a c i t y h a s b e e n p r o v i d e d f o r t h e f o l l o w i n g u n i t s :
N a p h t h a H y d r o t r e a t i n g U n i t 251 - 15 days
F-T P r o d u c t H y d r o t r e a t i n g U n i t 253 - 15 days
C a t a l y t i c R e f o r m i n g U n i t 255 - 5 days
C a t a l y t i c P o l y m e r i z a t i o n U n i t 257 - 2 days

O f f s i t e Units

The o f f s i t e u n i t s are d e s i g n e d f o r a minimum o f t w o p a r a l l e l

trains. I n cases w h e r e c o m m e r c i a l - s i z e d e q u i p m e n t i s t o o l a r g e
w i t h two t r a i n s , t h e number of t r a i n s h a s b e e n i n c r e a s e d .

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US. GOVERNMENT PRINTING OFFICE: 1978-740-094/1291