` FLUOR DANIEL

SECTION TOC
SYNGAS GENERATION
PAGE 1 of 2
PROCESS MANUAL TABLE OF CONTENTS
DATE 08-94

1.0 INTRODUCTION
1.1 DEFINITIONS
1.2 USES
1.3 FEEDSTOCKS
1.3.1 Natural Gas
1.3.2 Coal/Coke
1.3.3 Lignite
1.3.4 Orimulsion
1.3.5 Heavy Oil
1.3.6 Refinery Off-Gas
1.3.7 Sewage Sludge
1.4 H2 TO CO RATIO
1.5 REFERENCES

2.0 MANUFACTURING TECHNIQUES

2.1 REFORMING
2.1.1 Tubular Reforming
2.1.2 Adiabatic Reforming
2.1.3 Secondary Reforming
22 POX
2.2.1 Partial Oxidation of Oil
2.2.2 Partial Oxidation of Gas
2.3 COAL GASIFICATION
2.3.1 Texaco Coal Gasification Process
2.3.2 Shell Coal Gasification Process
2.3.3 DOW/DESTEC Coal Gasification Process
2.3.4 Other Coal Gasification Processes
2.4 REFERENCES

3.0 PROCESS CALCULATIONS

3.1 SIMULATIONS WITH GPC
3.1.1 GPC Tubular Reformer Calculations
3.1.2 GPC Auto Thermal Reformer Calculations
3.1.3 GPC Partial Oxidation Calculations
3.1.4 GPC Coal Gasification Calculations
3.1.5 GPC COS Hydrolysis/CO Shift/Methanation Calculations
3.1.6 Other GPC Equipment Calculations
3.1.7 Overall Plant Simulations Using the P00l File
3.2 OTHER SIMULATORS
3.2.1 H2PSA1 Program

4.0 LICENSOR/VENDOR INTERFACES

4.1 INTRODUCTION
4.2 LICENSOR/VENDOR CONTACTS

K:\WRK090\037\345\MANUALS\SYNGAS\009-TOC.SAM-04/23/1997
 ` FLUOR DANIEL
SECTION TOC
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL TABLE OF CONTENTS
DATE 08-94

5.0 EQUIPMENT CONSIDERATIONS

5.1 REFORMER
5.2 GASIFIER (REFRACTORIES, BURNER, ASH REMOVAL)
5.3 WASTE HEAT RECOVERY
5.3.1 Process Gas Boilers
5.3.2 Convection Section or HRSG
5.4 PARTICULAR REMOVAL/SCRUBBING
5.5 PROCESS CONDENSATE TREATMENT
5.6 OXYGEN PLANTS
5.7 SOLID FEED SYSTEMS
5.8 SHIFT REACTORS
5.9 ACID GAS REMOVAL
5.10 REFERENCES

6.0 APPENDIX
6.1 LIST OF MAJOR FLUOR DANIEL PROJECTS
6.2 GASIFICATION EXPERIENCE BY TECHNOLOGY
6.3 UTILITIES CONSUMPTION AND PRODUCTION
6.4 COST ESTIMATE
6.4.1 Data Base
6.4.2 Other
6.5 SALES QUALIFICATION DOCUMENTS
6.6 LIST OF NORMALIZED UNITS

K:\WRK090\037\345\MANUALS\SYNGAS\009-TOC.SAM-04/23/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 1 of 17
PROCESS MANUAL INTRODUCTION
DATE 08-94

1.0 INTRODUCTION

Scope and Objective of Manual

This manual presents an overview of the various design aspects of Syngas Generation.
It is meant to provide the user with the following basic information:

- What is syngas?

- What are its end uses?

- Which technologies are available for its manufacture and what are the suitable
feedstocks?

- Process descriptions of such manufacturing techniques.

- Process calculations of gasification and associated unit operations.

- Licensors and vendor interfaces.

- Equipment considerations.

- Reference sources for pertinent information.

Syngas can be produced by any of several proven technologies utilizing different

feedstocks. The intent of this manual is to acquaint the reader with different syngas
technologies and their environmental and economic implications. This manual is
intended to serve as a guide in selecting a specific syngas technology, using a given
feedstock, for a particular end use.

Some of the information included in this manual are old and should be used for
information only and not for design purposes. All proposed design activities should be
based on project-specific current licensor data accounting for various process variables.
Fluor Daniel has been actively involved in the current design of the major gasification
processes such as the Texaco coal, coke, Orimulsion and resid gasification processes
and the Shell resid gasification process. The information pertaining to these are
considered confidential. However, considerable current non-confidential information can
be gathered form the Fluor Daniel engineers who have been involved in the recent
gasification design activities.

Limitations

The feedstocks to manufacture syngas and its end uses are quite varied. This manual is
intended to be a general reference book for key process and mechanical design aspects
of syngas plants. The following factors need to be considered prior to selecting any
particular technology:

- Feedstock (cost, availability and suitability)

- Client preference for a particular technology
- End products
- Environmental considerations

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL INTRODUCTION
DATE 08-94

- Capital cost parameters

- Other economic factors

Because of the confidential nature of certain licensed processes, many technical design
details are not included in this manual.

1.1 DEFINITIONS

Raw syngas is produced by gasification of carbonaceous materials such as coal, coke,

natural gas, heavy oil, Orimulsion, etc or by reforming of natural gas or light hydrocarbon.
The primary constituents of raw syngas are carbon monoxide and hydrogen. However,
small amounts of carbon dioxide, methane (and heavier hydrocarbons for low
temperature gasification processes), ammonia, cyanide, formate, hydrogen sulfide,
carbonyl sulfide, and other compounds will be present in the syngas. For most
applications, as in gas turbine power plants, the raw syngas is processed to remove
sulfur and nitrogen compounds before it is combusted. Syngas with low calorific value,
often called producer or power gas, is a suitable gas turbine fuel for the generation of
electricity.

1.2 USES

Syngas can be used to produce the following major products:

Electricity by combusting syngas in a gas turbine

Hydrogen
Methanol
Carbon Monoxide
Oxo-alcohols
Acetic Anhydride
Liquid fuels
Ammonia

A list of products and their end uses is given below:

Product Use

Hydrogen Chemical Plants

Ammonia Manufacture (with addition of N2 from air)
Refineries

Carbon Monoxide Oxo-Chemicals

Carbon Dioxide Enhanced Oil Recovery

Food Preparation

Sulfur Sulfuric Acid Production

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 3
PROCESS MANUAL INTRODUCTION
DATE 08-94

1.3 FEEDSTOCKS

A variety of feedstocks can be used to produce the syngas. These feedstocks include:

Natural Gas
Lignite
Orimulsion (Heavy Oil/Water)
Coal/Coke
Heavy Oil
Refinery Off-gas
Sewage Sludge

1.3.1 Natural Gas

Natural gas is one of the best feedstocks for syngas production because it is
easily converted to syngas via steam reforming or POX. Current estimates
indicate that the lower 48 states in the U.S. have over a 60 year supply of natural
gas. Typical natural gas characteristics are listed in Table 1-1(3).

1.3.2 Coal/Coke

Coal is one of the most abundant, naturally occurring materials in the United
States. Composition of a particular coal feedstock may vary depending upon its
source. It is generally classified by its "type" and "rank." Coal type is determined
by the nature of the plant material from which it is originated. Rank is the most
important property of coal and signifies the degree of maturation in the process
of coal formation or "coalification." Generally, the lower the coal rank, the lower
is the calorific value and the higher the content of moisture and volatile matter.
In Figure 1-1(1), properties defined by "proximate analysis" such as fixed carbon,
volatile matter and moisture in mass percent are shown for various types of coal.
The "proximate analyses" are presented on an ash-free basis. The same figure
also shows the calorific value of various types of coal. More detailed definition of
properties is given by an ultimate analysis, a breakdown according to the five
elements: carbon, hydrogen, oxygen, nitrogen, and sulfur as well as ash
content. Table 1-2(1) presents typical ultimate analyses for coals from the major
fields in the United States. Typical characteristics of eastern bituminous coal
and Illinois No. 6 coal are given in Table 1-3 and Table 1-4(3), respectively.

Petroleum coke, obtained from coking process, can also serve as feedstock for
syngas production. Chemical analysis of fluid coke derived from Boscan crude is
listed in Table 1-5(4).

1.3.3 Lignite

Lignite is the lowest ranked coal, followed in increasing rank by subbituminous

coal, bituminous coal and anthracite. Generally, lignite has lower fixed carbon
content and higher oxygen and hydrogen content than the other types of coal.
This comparison is shown in Table 1-6. Proximate, ultimate and ash analysis for
typical Texas lignite is given in Table 1-7(3).

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 4
PROCESS MANUAL INTRODUCTION
DATE 08-94

Figure 1-1

1.3.4 Orimulsion

Orimulsion is a trade name of a man-made water-bitumen mixture, containing an

appreciable quantity of vanadium, nickel, alkali and alkali-earth metals such as
sodium, magnesium and traces of other heavy metals, particularly iron. It
contains nominally about 4.0 % sulfur (dry basis). The correct water content for
gasification and relatively low cost ($/MM Btu) make Orimulsion an attractive
feed stock for syngas production. Bitumen, extracted by steam injection, is
degasified before brine is separated from it. Fresh water is added to comprise
about 30 wt% in the final Orimulsion product. Additives, which make up less
than 1 % of the final product, are mixed with Orimulsion to stabilize the emulsion
for transport. The Orimulsion temperature is maintained between 41 oF and
176 oF during transportation and storage. Typical Orimulsion characteristics are
listed in Table 1-8(5).

1.3.5 Heavy Oil

Heavy oil refers to high boiling hydrocarbons that are relatively low in hydrogen
content, highly viscous and contain sulfur, nitrogen and small quantity of ash.
Atmospheric resid, vacuum resid and asphalt are typical examples of heavy oil.
The characteristics of a typical vacuum resid as a feed to a visbreaking unit are
given in Table 1-9.(3)

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 5
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-1

TYPICAL NATURAL GAS CHARACTERISTICS

Component Mol %

Methane 97.00

Ethane 1.80

Carbon Dioxide 0.44

Propane 0.29

Nitrogen 0.27

N-Butane 0.06

I-Butane 0.05

Pentane 0.03

Hexane 0.03

Heptane 0.01

Helium 0.01

Octane 0.00

Oxygen 0.00

Argon 0.00

Sulfur 5.5 grains

Higher Heating Value (HHV), Btu/ft3 1,030

Specific Gravity 0.582

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 6
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-2

ULTIMATE ANALYSES IN MASS PERCENT OF REPRESENTATIVE

COALS OF THE UNITED STATES

Fort Union Powder River Four Corners Illinois Appalachian

Component Lignite Subbituminous Subbituminous Bituminous Bituminous

Carbon 39.9 45.8 47.5 60.1 73.6

Hydrogen 2.8 3.4 3.6 4.1 4.9

Oxygen 11.0 11.3 9.3 8.3 5.3

Nitrogen 0.6 0.6 0.9 1.1 1.4

Sulfur 0.9 0.7 0.7 2.9 2.8

Moisture 36.2 30.4 12.4 16.1 2.3

Ash 8.6 7.8 25.6 7.4 9.7

Total 100.0 100.0 100.0 100.0 100.0

Gross Calorific Value 15.6 18.4 19.6 24.9 31.2

(GCV), MJ/kg

Higher Heating Value 6,708 7,912 8,428 10,707 13,416

(HHV), Btu/lb

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 7
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-3

TYPICAL CHARACTERISTICS OF EASTERN BITUMINOUS COAL

Moisture Free As Received

Design Performance Design Performance
Range Coal Range Coal
Proximate Analysis, wt%
Fixed Carbon - 66.2 - 61.9
Volatile Matter 14 - 43 19.0 13 - 40 17.7
Moisture - 5 - 10 6.5
Ash 6 - 16 12.8 5.6 - 15 12.0
Sulfur 1.4 - 4 2.0 1.4 - 3.7 1.9

HHV, Btu/lb(a) 12,800 - 13,800 13,200 12,000 - 12,900 12,400

Ultimate Analysis, wt%

Carbon 70 - 85 75.6 65.5 - 79.6 70.7
Hydrogen 4.0 - 5.6 4.3 3.7 - 5.2 4.0
Oxygen 2.1 - 10.0 3.9 2.0 - 9.9 3.6
Nitrogen 1.0 - 1.8 1.4 1.0 - 1.7 1.3
Sulfur 1.5 - 4.0 2.0 1.5 - 3.7 1.9
Moisture - - 5 - 10 6.5
Ash 6 - 16 12.8 5.6 - 15 12.0
Total 100.0 100.0

Chlorine 0.01 - 0.25 0.13 0.01 - 0.25 0.13

Fluorine 0.002 - 0.01 - 0.002 - 0.01 -

Ash Softening Temperature- 2,000 - 2,800 2,500 2,000 - 2,800 2,500

Reducing Atmosphere, oF

Notes:
(a) Higher Heating Values presented for performance coal are approximate.

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 8
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-4

TYPICAL CHARACTERISTICS OF ILLINOIS NO. 6 COAL

Proximate Analysis - "As Received," wt%

Fixed Carbon 47.8
Volatile Matter 31.4
Moisture 12.0
Ash 8.8
100.0
Ultimate Analysis - Dry and Ash-Free, wt%
Carbon 77.26
Hydrogen 5.92
Oxygen 11.14
Nitrogen 1.39
Sulfur 4.29
100.00
Ash Analysis - High Temperature Ashing, wt%
SiO2 45.0
Al203 18.0
Fe203 20.0
TiO2 1.0
CaO 7.0
MgO 1.0
SO3 3.5
K2O 1.9
Na20 0.6
P205 0.2
Unknown 1.8
100.0
Ash Fusion Analysis
Reducing Oxidizing
Atmosphere Atmosphere
Initial Deformation, oF 1,950 2,250
Softening Temperature, oF 2,030 2,300
Hemispherical Temperature, oF 2,140 2,430
Fluid Temperature, oF 2,150 2,450

Heating Value - "As Received"

Higher Heating Value (HHV) = 11,241 Btu/lb

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 9
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-5

FLUID COKE CHARACTERISTICS - DERIVED FROM BOSCAN CRUDE

Chemical Analysis of Coke (Dry), wt%

Carbon 85.98

Hydrogen 2.00

Oxygen 2.27

Nitrogen 0.98

Sulfur 8.31

Ash 0.46

Vanadium 4,075 ppm

Nickel 440 ppm

Iron 75 ppm

The coke leaving the fluid coker unit at 200 oC resembles a coarse hot powder with a particle size
distribution as follows:
Particle Size Distribution of Coke

Cumulative wt% less

Size than

Mesh Micron

325 44 1

200 74 5

150 105 15

100 149 40

65 210 70

48 297 90

35 420 95

Ash fusion analysis is obtained from licensor.

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 10
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-6

CARBON, HYDROGEN, OXYGEN COMPARISON AMONG COALS AND OTHER

FEEDSTOCKS

Chemical Change With Coal Rank

Material Weight Percent(b)

Carbon Hydrogen Oxygen

Wood (cellulose) 44 6 50

Peat(a) 59 6 35

Lignite 71 5 24

Subbituminous coal 74 5 21

Bituminous coal 84 5 11

Anthracite 94 3 3

Graphite 100 - -

Notes:
(a) Not a coal
(b) Values are representative averages

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 11
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-7

CHARACTERISTICS OF TEXAS LIGNITE

Proximate Analysis - "As Received," wt%

Fixed Carbon 29.0
Volatile Matter 25.3
Moisture 34.9
Ash 10.8
100.0
Ultimate Analysis - Dry and Ash-Free, wt%
Carbon 73.02
Hydrogen 5.38
Oxygen 18.96
Nitrogen 1.28
Sulfur 1.36
100.00
Ash Analysis - High Temperature Ashing, wt%
SiO2 42.5
Al203 21.0
Fe203 9.8
TiO2 1.2
CaO 10.9
MgO 2.9
SO3 10.1
K2O 0.3
Na20 0.4
P205 0.1
Unknown 0.8
100.0
Ash Fusion Analysis
Reducing Oxidizing
Atmosphere Atmosphere
Initial Deformation, oF 1,910 2,040
Softening Temperature, oF 2,130 2,200
Hemispherical Temperature, oF 2,180 2,240
Fluid Temperature, oF 2,190 2,260

Higher Heating Value (as received) = 6,826 Btu/lb

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 12
PROCESS MANUAL INTRODUCTION
DATE 08-94

1.3.6 Refinery Off-Gas

Refinery off-gas is a mixture of gases generated by thermal and catalytic process

in various refinery units. It is often used as a fuel in the refinery. The
composition of refinery off-gas will vary significantly depending upon types of
process units in a particular refinery.

1.3.7 Sewage Sludge

Sewage sludge produced in a municipal treatment facility contains 20-25 wt%

solids. This can be a potential gasifier feedstock after proper pretreatment. The
pretreatment for a slurry feed based gasifier consists of further drying of the
sewage sludge and mixing it with coal slurry. The sewage sludge typically
commands a tipping fee for environmentally benign disposal and the gasification
route, based on pilot plant tests, has proven to be an acceptable means of
sludge disposal.

1.4 H2 TO CO RATIO

The major components of syngas are hydrogen and carbon monoxide. These two
components can be reacted to form a number of different products by using suitable
catalysts. Coal gasifiers typically produce syngas having a H2/CO ratio less than 1. For
further processing of this syngas to other chemicals, an adjustment to the H2/CO ratio is
normally required and is done using the shift reaction by catalytically reacting the carbon
monoxide in the syngas with moisture in the syngas or with added steam to form
hydrogen and carbon dioxide.

Shift Reaction
→
CO + H2O ← CO2 + H2

The shift reaction is exothermic and, therefore, the equilibrium yields of hydrogen
decrease with increasing temperature.

As discussed earlier, synthesis reactions take place under varying process temperature/
pressure conditions to produce different products like methane, methanol, gasoline,
mixed alcohols or other liquid fuels. Prevention of carbon formation during synthesis
reactions is of considerable commercial importance because the carbon deactivates the
catalyst by deposition on active sites. Equilibrium studies of carbon deposition indicate
that, in general, increasing the H2/CO ratio combined with decreasing temperature
reduces the probability of carbon deposition in synthesis reactors.

H2/CO ratios in product syngas obtained from different feedstocks using Texaco
gasification process are listed in Table 1-10(6) and Table 1-11(7).

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 13
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-8

ORIMULSION (a) CHARACTERISTICS

Water content, - "as received," wt% 30 (nominal)

Median droplet size, micron 20
Droplets @ 100 microns 1.5 %
3
Density, lb/ft 63
Apparent viscosity
41F/20 sec-1 700 mPa
86F/20 sec-1 450 mPa
158F/100 sec-1 150 mPa
Vanadium content, ppm (as received) 300
Sodium content, ppm (as received) 70
Magnesium content, ppm (as received) 350
o
Flash point, F 266
o
Pour point, F 32
Elemental analysis - "as received," wt%
Carbon 60.00
Hydrogen 7.50
Oxygen 0.20
Nitrogen 0.50
Sulfur 2.70
Moisture 28.85
Ash 0.25
100.00

Higher Heating Value (HHV), Btu/lb (as received) 12,683

Lower Heating Value (LHV), Btu/lb (as received) 11,694

(a) Trade name of PdVSA

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 14
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-9

TYPICAL HEAVY OIL CHARACTERISTICS

Source Arab Heavy

TBP Cut Range Vacuum Resid

Gravity, API 4.6

Sulfur, wt% 5.25

Nitrogen by mass, ppmw 4,100

Ni & V by mass, ppmw 223

Conradson Carbon Residue (CCR), wt% 24.2

Viscosity, cs @ 210 oF 11,000

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 15
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-10

H2/CO RATIO IN SYNGAS GENERATED FROM VARIOUS FEEDSTOCKS

(TEXACO GASIFICATION PROCESS)

COAL PETROLEUM COAL LIQUEF

COKE _RESIDUE _
FEED TYPE PITTSB. NO. FRENCH UTAH GERMAN S. AFRICAN DELAYED FLUID MOLTEN SLURRY
8
Feedstock (Dry), wt%
Carbon 74.16 78.08 68.21 73.93 65.60 88.50 85.98 68.39 68.39
Hydrogen 5.15 5.26 4.78 4.65 3.51 3.90 2.00 4.75 4.75
Oxygen 6.70 8.23 15.69 5.85 7.79 0.10 2.27 2.21 2.21
Nitrogen 1.18 0.85 1.22 1.50 1.53 1.50 0.98 0.98 0.98
Sulfur 3.27 0.47 0.37 1.08 0.87 5.50 8.31 1.87 1.87
Ash 9.54 7.11 9.73 13.01 20.70 0.50 0.46 21.80 21.80
Higher Heating Value
Btu/lb 13,600 14,000 11,800 13,200 11,200 15,400 13,800 12,700 12,700
Kcal/kg 7,540 7,780 6,570 7,330 6,220 8,550 7,665 7,060 7,060
Product Composition,
mol %
Carbon Monoxide 39.95 37.36 30.88 39.46 36.53 46.20 47.14 46.31 33.48
Hydrogen 30.78 29.26 26.71 29.33 26.01 28.69 24.33 35.54 28.56
Carbon Dioxide 11.43 13.30 15.91 12.59 15.67 10.68 13.16 6.41 13.09
Water 16.43 19.43 25.67 17.47 20.82 12.37 12.67 10.46 23.72
Methane 0.04 0.16 0.22 0.25 0.02 0.17 0.09 0.27 0.23
Nitrogen & Argon 0.49 0.37 0.50 0.60 0.68 0.55 0.42 0.45 0.42
Hydrogen Sulfide + 0.88 0.12 0.11 0.30 0.27 1.34 2.19 0.56 0.50
Carbonyl Sulfide
H2/CO Ratio, mol/mol (a) 0.77 0.78 0.86 0.74 0.71 0.62 0.52 0.77 0.85

(a) Table does not account for process differences in pressure and temperature.

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 16
PROCESS MANUAL INTRODUCTION
DATE 08-94

Table 1-11

H2/CO RATIO IN SYNGAS GENERATED FROM VARIOUS FEEDSTOCKS

(TEXACO GASIFICATION PROCESS)
Natural 64 o API 9.6 o API 9.6 o API 4.3 o API H-Oil 0 o API
FEED TYPE Gas Naphtha Fuel Oil Fuel Oil Vac Resid Bottoms Asphalt
Composition, wt%
Carbon 73.40 83.80 87.20 87.2 83.80 84.33 84.60
Hydrogen 22.76 16.20 9.90 9.9 9.65 8.89 8.91
Oxygen 0.76 - 0.80 0.8 - - 0.78
Nitrogen 3.08 - 0.70 0.7 0.31 1.12 0.68
Sulfur - - 1.40 1.4 6.20 5.56 4.90
Ash - - - - 0.04 0.10 0.13
C/H Ratio, kg/kg 3.22 5.17 8.82 8.82 8.68 9.49 9.50
Higher Heating Value
Btu/lb 22,630 20,300 18,200 18,200 17,330 17,084 17,099
kcal/kg 12,572 11,278 10,111 10,111 9,628 9,491 9,499
Flow Rates, per thousand normal cubic meters of dry product gas
Hydrocarbon, kg 276.8 313.6 340.9 329.8 346.1 390.0 357.6
Steam, kg - 78.3 156.8 186.9 173.1 158.7 182.0
Oxygen, Nm3 248 239 240 241 245 418 268
Carbon, kg - 1.9 10.8 (a) (a) (a) (a)
Product Gas Composition, mol %
Carbon Monoxide 35.0 45.3 48.5 47.5 48.3 51.2 49.3
Hydrogen 61.1 51.2 45.9 45.8 44.2 41.4 42.1
Carbon Dioxide 2.6 2.7 4.6 5.7 5.2 5.3 6.5
Methane 0.3 0.7 0.2 0.5 0.6 0.3 0.4
Nitrogen Plus Argon 1.0 0.1 0.7 0.2 0.2 0.4 0.4
Hydrogen Sulfide - - 0.1 0.3 1.4 1.3 1.2
Carbonyl Sulfide - - - - 0.1 0.1 0.1
Performance Data
Specific Oxygen Consumption, Nm3 (O2)/103Nm3 (H2 + CO) 255 248 254 258 265 292 292
Cold Gas Efficiency, % HHV of Feed/HHV of (H2 + CO) 83.8 82.7 83.1 84.7 84.1 82.0 81.9
H2/CO ratio, mol/mol(b) 1.75 1.13 0.95 0.96 0.92 0.81 0.85

Notes:
(a) Recycled to extinction.
(b) Table does not account for process difference in pressure and temperature.

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 1.0
SYNGAS GENERATION
PAGE 17
PROCESS MANUAL INTRODUCTION
DATE 08-94

1.5 REFERENCES

1. "Synthetic Fuels" by R.F. Probstein and R. Edwin Hicks, Pages 13 - 14,

McGaw-Hill Publication, 1982.

2. "Evaluation of Texaco Gasification - Combined cycle Plant with Kraft Werk Union
Gas Turbines, EPRI GS-6160, Project 2699-10 Final Report, December 1988,
Pages 2 - 7.

3. Copyright 1983. Electric Power Research Institute. EPRI AP-3129. Shell

based gasification-combined-cycle power plant evaluation. Reprinted with
permission.

4. Description of the Texaco Gasification Process and its secondary systems for
the ELF Project, Page 12.

5. "New Fuel Could find niche between oil, coal" Power, Page 51, December 1991.

6. "Texaco Gasification Process for Solid Feedstocks" - Texaco Development

Corporation, 1993.

7. "The Texaco Synthesis Gas Generation Process" - Texaco Development

Corporation, January 1984.

K:\WRK090\037\345\MANUALS\SYNGAS\009-01.SAM-04/24/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 1 of 45
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

1.0

2.0 MANUFACTURING TECHNIQUES

Syngas can be manufactured by various processes using a wide variety of feedstocks. Typical
feedstocks are listed in Section 1.3. Three major manufacturing techniques used to produce
syngas are:

Reforming.
POX (partial oxidation) of oil or gas.
Coal/Petroleum coke gasification.

Quite often, the end usage of syngas and available feedstock determine the selection of a
specific manufacturing technology to produce syngas. In addition, the following factors may
significantly impact selection of a specific syngas manufacturing technology:

Economic factors - Capital cost, operating and maintenance costs, fuel cost, product
cost, cost of electricity, cost of oxygen (if purchased), dispatchability (base load,
intermediate load, peaking).

Client preference.

Feed availability/cost and product requirements.

Environmental considerations - emissions, effluents, solid wastes, other air toxics,

mitigation, offsets, and water conservation.

Other factors - Transmission access, reliability and availability considerations, and

natural resources/employment base.

2.1 REFORMING

2.1.1 Tubular Reforming (Refer to Figure 2-1)

The traditional way of producing synthesis gas employs Hydrocarbon Steam

Reforming (HSR) technology with the following characteristics:

Processing of hydrocarbons ranging from natural gas through

straight-run naphtha with a final boiling point of 430 oF maximum.

Large process steam requirement.

No feed oxygen requirement.

Ability to avoid carbon formation.

Reformer Tube Outlet temperatures between 1,450 oF and 1,650 oF.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-1

TYPICAL HYDROCARBON STEAM REFORMING PROCESS

Reactor outlet pressures up to 450 psig.

Catalyst required.

Very low tolerance for feed sulfur, halogens, olefins, and most metals.

Large, complex, direct fired furnace with high alloy metal internals and
headers.

H2/CO ratios unfavorable for methanol, oxoalcohol and Fischer-Tropsch

Synthesis.

2.1.2 Adiabatic Reforming (Refer to Figure 2-2)

An alternative process for synthesis gas production employs Partial Oxidation

(POX) or Gasification. This technology is characterized by:

A large variety of feedstocks including natural gas, refinery offgas, fuel

oil, asphalt, coke, lignite and coal.

Small or no process steam requirement.

Feed air or oxygen requirement, i.e., air-blown or oxygen-blown reactor,

the latter requiring an oxygen supply from an air separation unit.

Inability to totally avoid carbon formation which may cause metal dusting.

Discharge temperatures above 1,700 oF.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 3
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-2

TYPICAL AUTOTHERMAL REFORMING PROCESS

Discharge pressures up to 1,200 psig.

No catalyst requirements for high temperature applications, i.e.,

Gasification or Thermal Partial Oxidation (TPO). Catalyst is required at
lower temperatures i.e., Catalytic Partial Oxidation (CPO) or Autothermal
Reforming.

High tolerance for feed impurities for applications without catalyst.

Small, refractory-lined reactor.

H2/CO ratios favorable for methanol, oxoalcohol and Fischer-Tropsch

synthesis.

2.1.3 Secondary Reforming

A design which combines an steam reforming furnace in series with a POX

reactor is often selected to distribute the overall steam reforming duty between
the two units such that an optimum balance is achieved with regards to overall
investment and operating cost.

The classical example for such a design is found in the ammonia plants
processing light feeds such as natural gas and straight-run naphthas. Since
nitrogen must be introduced into the process, these particular designs introduce

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 4
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

air rather than oxygen into the POX reactor which also normally contains
reforming catalyst, operating at outlet temperatures below 1,900 oF.

This type of catalytic reactor is called a Secondary Reformer or Auto Thermal

Reformer (ATR). If the synthesis gas must be free of nitrogen, oxygen is
substituted for the air to the ATR and the HSR/ATR combination is often called
Combi Reforming, a term coined by Lurgi.

The sensible heat available at the exit of the ATR can be used to generate steam
in a conventional process gas cooler/steam generator. Alternatively the heat
may serve to satisfy the process heat requirements of the HSR such as ICI's
Leading Concept Ammonia (LCA) process which utilizes a Gas Heated Reformer
(GHR) to convectively cool the hot process gas stream leaving the ATR.(1) Fluor
Daniel's Adiabatic Reformer (Adreformer) accomplishes the same operation in
one vessel by mechanically integrating the ATR with the GHR.(1)

Following is a brief description of the various Combi Reforming scenarios

presently used or considered in the industry including technical comments and a
brief review of the current state of development, if known.

Figure 2-3 shows how ICI employs the hot process gas from the ATR to provide
the heat for the endothermic steam reforming reaction in the catalyst filled tubes
of the GHR. Two 450 mtpd LCA ammonia plants were successfully
commissioned in the U.K. and proved the validity of the concept.

Figure 2-3

ICI GHR/ATR REFORMING

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 5
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

A 160 Mtpd methanol research plant employing ICI's Leading Concept Methanol
(LCM) process will be built by bhp petroleum in Melbourne at a cost of about
U.S. $50 million as the first step towards utilizing the currently uneconomical
offshore gas reserves.

The difference between LCA and LCM is the oxidant (LCA uses air while LCM
uses oxygen). Oxygen is difficult to handle as it favors high local reactor
adiabatic flame temperatures. The ATR burner requires stringent mixing to
prevent local overheating of the burner and the reactor refractory.

Air Products and Chemicals, Inc. developed the Enhanced Heat Transfer
Reformer (EHTR).(3) The EHTR effectively utilizes the high temperature energy
of the reformed gas to convert additional natural gas to syngas rather than
generating steam. Figure 2-4 depicts a design using an EHTR in combination
with an HSR and an ATR.

Figure 2-4

AIR PRODUCTS EHTR PROCESS

Another successful design that combines an HSR furnace with an oxygen-blown

POX reactor is shown in Figure 2-5. Part of the feed can bypass the HSR to
achieve a lower overall steam consumption and lower H2/CO ratios without
increasing the risk of carbon formation in the HSR. The concept was developed
by Lurgi and has been commercialized for large scale production of syngas for
Fischer-Tropsch liquids and methanol production.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 6
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Primary reforming alone can produce syngas with H2/CO ratios lower than 3.0 (or
"Riblett"(a) ratios near 1.0) only by adding CO2 to the reformer feed.

Figure 2-5

LURGI HSR/ATR COMBI REFORMING

The patented Fluor Daniel Adiabatic Reformer (Adreformer) features full

integration of a convective reformer with an ATR in one vessel as shown in
Figure 2-6. Recent 20 mtpd pilot plant tests proved the viability of the concept.
The ATR burners have been fabricated to withstand the high temperature
environment encountered with oxygen feed.

A reactor similar to Fluor Daniel's Adreformer was developed and tested by

Uhde. However, as shown in Figure 2-7, Uhde's Combined Autothermal
Reformer (CAR) contains a non-catalytic ATR.(5)

Other convective reformer configurations with or without an ATR are described

by:

The British Petroleum Company(6)

Mitsubishi Gas Chemicals
The M.W. Kellogg Company(7)
Union Carbide
Stone & Webster(8)
Chiyoda(9)

Notes:
(a)
The Riblett ratio is often used to characterize syngas. The ratio is defined as the molar ratio
H2/(2CO + 3CO2). A Riblett ratio of 1.0 is the "ideal" feedstock for a methanol synthesis reactor.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 7
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-6

FLUOR DANIEL'S ADREFORMER

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 8
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

2.2 POX

General

The function of the partial oxidation hydrogen unit is to convert heavy refinery residues,
either oils or coke, to a synthesis gas which can be converted further to hydrogen
product. Conversion of the residue to synthesis gas is accomplished at a high
temperature in the presence of steam and a sub-stoichiometric quantity of oxygen. Feed
Oil is pumped directly into the reactor where steam is introduced. In the case of coke
coke feed must first be ground and slurried with water to produce a pumpable mixture.
With coke feed, the unconverted carbon can be recovered as a recyclable water slurry by
settling or filtration. With oil feed the carbon-containing soot must be extracted from the
water phase by using naphtha for eventual recycle to the reactor or by using filtration. A
blowdown water stream from the partial oxidation area is treated for contaminant removal
prior to disposal.

Table 2.2-1(10) lists the properties and performance data for typical raw materials. All
rates are per thousand normal cubic meters of dry product gas. Comparative data for no
soot recycle and 100 percent soot recycle are also given. This table illustrates how the
oxygen requirements, synthesis gas cold efficiency, and the hydrogen to carbon
monoxide ratio of the product gas are largely dependent upon the feed material.

Thermodynamics and Chemistry

The Texaco Synthesis Gas Generation Process is a non-catalytic partial oxidation

process in which gaseous or liquid carbonaceous substances including petroleum
residues react at high temperature and usually at high pressure with oxygen, oxygen
enriched air, or air, according to the basic overall reaction:

CH + 1 O 2 → CO + 1 H 2
2 2

Although the detailed chemistry and thermodynamics of partial oxidation technology are
very complex, valuable insight can be gained by considering two additional concurrent
reactions, the complete oxidation of the hydrocarbon fragment to carbon dioxide and
water,

CH + 5 O 2 → CO 2 + 1 H 2 O
4 2

and the reversible water-gas shift reaction,

→
CO + H 2 O ← CO 2 + H 2

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 9
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Table 2-1

Natural 64o API 9.6o API 9.6o API 4.3oAPI H-Oil 0o API
FEED TYPE Gas Naphtha Fuel Oil Fuel Oil VacResid Bottoms Asphalt
Composition, wt%
Carbon 73.40 83.80 87.20 87.20 83.80 84.33 84.60
Hydrogen 22.76 16.20 9.90 9.90 9.65 8.89 8.91
Nitrogen 3.08 -- 0.70 0.70 0.31 1.12 0.68
Sulfur -- -- 1.40 1.40 6.20 5.56 4.90
Oxygen 0.76 -- 0.80 0.80 -- -- 0.78
Ash -- -- -- -- 0.04 0.1 0.13
C/H Ratio, kg/kg 3.22 5.17 8.82 8.82 8.68 9.49 9.50
Higher Heating Value
kcal/kg 12,572 11,278 10,111 10,111 9,628 9,491 9,499
Btu/lb 22,630 20,300 18,200 18,200 17,330 17,084 17,099
Flow Rate, per thousand normal cubic meters of dry product gas
Hydrocarbon, kg 276.8 313.6 340.9 329.8 346.1 390 357.6
Steam, kg -- 78.3 156.8 186.9 173.1 158.7 182.0
3
Oxygen, Nm 248 239 240 241 245 418 268
Carbon, kg -- 1.9 10.8 (a) (a) (a) (a)
Product Gas Composition, mol %
Carbon Monoxide 35.0 45.3 48.5 47.5 48.3 51.2 49.3
Hydrogen 61.1 51.2 45.9 45.8 44.2 41.4 42.1
Carbon Dioxide 2.6 2.7 4.6 5.7 5.2 5.3 6.5
Methane 0.3 0.7 0.2 0.5 0.6 0.3 0.4
Nitrogen Plus Argon 1.0 0.1 0.7 0.2 0.2 0.4 0.4
Hydrogen Sulfide -- -- 0.1 0.3 1.4 1.3 1.2
Carbonyl Sulfide -- -- -- -- 0.1 0.1 0.1
Performance Data
Specific Oxygen
Consumption 255 248 254 258 265 292 292
NM3(O2)/MNm3(H2+CO)
Cold Gas Efficiency (% HHV of
CO+H2/HHV of Feed) 83.8 82.7 83.1 84.7 84.1 82.0 81.9
H2/CO ratio, mol/mol 1.75 1.13 0.95 0.96 0.92 0.81 0.84

Notes:
(a) Recycled to extinction.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 10
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Both of these reactions are exothermic and require the use of a temperature moderator
such as water, steam or carbon dioxide to control the reaction temperature.

The raw gas mixture contains principally carbon monoxide and hydrogen, with some
carbon dioxide and steam, plus trace amounts of argon, nitrogen, ammonia, formate,
cyanide, methane, and (if the feed contained sulfur) hydrogen sulfide and carbonyl
sulfide. Since the gasifier operates in a highly reducing atmosphere, there are no oxides
of sulfur or nitrogen in the product gas.

2.2.1 Partial Oxidation of Oil

The description of the Texaco Synthesis Gas Generation Process (TSGGP) for
partial oxidation of oil is as follows:

The gasifier is a refractory-lined pressure vessel. The liquid or gaseous

feedstock, moderator and oxidant enter through a specially-designed top
mounted burner and flow concurrently downwards. Figures 2-8(10) and 2-9(10)
show simplified flow schemes for liquid feed gasification. Hot synthesis gas from
the gasifier is cooled either directly in a quench chamber, indirectly in a syngas
cooler, or the gas stream is split with one stream cooled directly and the other
stream indirectly. The ultimate end-use generally determines the mode of gas
cooling.

Figure 2-8

OIL-FIRED GENERATOR WITH DIRECT QUENCH

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 11
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-9

OIL-FIRED GENERATOR WITH SYNGAS COOLER

The direct quench mode is normally selected for production of high purity
hydrogen. The hot gas exiting the gasifier contacts the quench water, cooling
the raw gas and saturating it with steam.

The raw synthesis gas is water-scrubbed to remove all traces of entrained

particles, principally unconverted carbon and the entrained fly ash. The steam
produced in the water quench of the hot syngas is sufficient to provide the
reaction water required downstream in the catalytic shift conversion step.
Utilizing the sensible heat of the process gas in this manner is an effective
method of raising the process steam required for the shift reaction. Waste heat
recovery of the shift effluent gas is accomplished by generating high pressure
steam.

For the manufacture of fuel gas, reducing gas or oxochemicals, the syngas
cooler mode is recommended. The cooling of the gas is carried out in a specially
designed cooler where high pressure steam for export is generated with
additional gas cooling in the economizer.

The split-flow mode of operation is used when the quenched portion of the
syngas is shifted such that the combination of the shifted gas and the unshifted
bypass gas streams has the desired H2/CO ratio for further chemical synthesis.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 12
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Liquid feed stocks produce a small yield of unconverted carbon on a single-pass

basis. In both modes, this unconverted carbon is transferred to the scrubbing
water. The water is mixed with an extractant, usually naphtha, in order to
transfer the carbon to the naphtha phase.

The soot-free water phase is routed to a water flash separator which removes
trace hydrocarbons before recycling the water to the syngas scrubber. The
soot/naphtha phase leaves the decanter as overhead and is routed to the
naphtha stripper. The naphtha is recovered in the stripper and recycled to the
decanter. The soot bearing stripper bottoms may be recycled to extinction in the
gasifier or burned as boiler fuel.

For those plants gasifying distillate fuels, carbon recovery is simplified by directly
transferring carbon from the quench water to the primary feedstock, eliminating
the need for the stripper. Gas fed units produce much less soot. The
unconverted carbon containing water can be recycled to the gasifier burner to
achieve complete carbon conversion.

2.2.2 Partial Oxidation of Gas

The description of the Texaco Synthesis Gas Generation Process (TSGGP) for
partial oxidation of gas is as follows:

Figure 2-10(10) depicts a simplified flow scheme for a gas feed with a syngas
cooler. Gaseous feed, natural gas or refinery fuel gas, does not normally require
moderator for temperature control. However, water, steam or carbon dioxide are
often used to adjust the product hydrogen to carbon monoxide ratio via the
water-gas shift reaction to that desired for a particular chemical synthesis
process. This feature allows the user to optimize the process continuously by
minimizing the feedstock requirements. Similarly, the feed gas is normally
preheated to reduce oxidant consumption and improve overall thermal efficiency.

2.3 COAL GASIFICATION

General

Coal gasification is a proven technology that has been improved significantly over the
past two decades. A number of technologies have been developed to convert coal into
syngas using moving-bed gasifiers, fluidized bed gasifiers or entrained-flow gasifiers.
However, only three gasification technologies of greatest interest to Fluor Daniel will be
discussed:

Texaco
Shell
Dow/Destec

For years, coal gasification has been used for production of hydrogen, syngas for fuels,
methanol, ammonia, acetic anhydride and other chemicals. In recent years, the utility
industry has shown an increased interest in the application of coal gasification plants
integrated with combined cycle power plants due to the environmental and plant

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 13
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-10

GAS-FIRE GENERATOR WITH SYNGAS COOLER

performance advantages over coal-fired boilers. For electrical power generation, the
process configuration of a typical gasification combined cycle (GCC) power plant using
coal gasification is illustrated in Figure 2-11.

Chemistry

In conventional generation of electric power from coal, coal is burned with air to make
steam that drives a turbine to produce electricity. Combustible matter in coal consists of
complex molecules made up principally of carbon and hydrogen. During combustion in
the boilers, oxygen in the air converts the combustible matter to carbon dioxide and
water and most of the carbon in the coal is converted to carbon dioxide. Excess air is
supplied to ensure complete combustion. In contrast, gasification consists of incomplete
combustion with a deficiency of oxygen supply, generally 1/5 to 1/3 of the amount
theoretically required for complete combustion to carbon dioxide and water. Carbon
monoxide and hydrogen, which are combustible gases, are among the most prominent
products of gasification. In gasification, only a fraction of the carbon in the coal is
oxidized completely to carbon dioxide. The heat released by partial combustion provides
the bulk of the energy necessary to break chemical bonds in the coal and raise the
products to reaction temperature.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 14
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-11

TECHNOLOGY OVERVIEW

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 15
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

When coal is subjected to the gasification condition (i.e., sub-stoichiometric oxygen), it is

first dried by evaporation of the surface and bound moisture. As the temperature rises,
devolatilization occurs, and the weaker chemical bonds are broken, and tars, oils,
phenols and hydrocarbon gases are formed. The fate of the devolatilization products
depends strongly on the conditions under which they are released. In moving-bed
gasifiers, devolatilization products exit the gasifier with the gas because of low
temperatures and lack of oxygen where they are released. In fluidized-bed and
entrained-flow gasifiers, uniform high temperatures cause cracking of the hydrocarbons
to occur. Also, oxygen reacts with the devolatilization products to produce hydrogen,
carbon monoxide and carbon dioxide. This happens to the greatest extent in
entrained-flow reactors with the production almost entirely of carbon monoxide, hydrogen
and carbon dioxide.

Fixed carbon, which remains after devolatilization, is gasified by reactions with oxygen,
steam, carbon dioxide, and hydrogen, and the gases react among themselves to produce
the final gas mixture. The water gas shift reaction is favored by low temperatures
affecting the H2/CO ratio but has little effect on the heating value of the product. The
following are important gasification reactions:

C + O2 = CO2 (exothermic, predominates at low temperatures)

C + ½O2 = CO (exothermic, predominates at high temperatures)

C + H2O = CO + H2 (endothermic, slower than the above reactions)

C + CO2 = 2CO (endothermic, slower than the above reactions)

H2O + CO = H2 + CO2 (exothermic, shift, rapid)

CO + 3H2 = CH4 + H2O (exothermic, methanation)

C + 2H2 = CH4 (exothermic, methanation)

The first five reactions are the most prominent in the gasification systems. However,
methane formation is important in the lower temperature systems. The methanation
reactions (the last two reactions) are favored by high pressures and low temperatures,
but in most cases methane concentration is higher than equilibrium would predict
because methane is also formed during devolatilization. Methane formation increases
the thermal efficiency of gasification and the heating value of the product.

The fate of trace elements such as sulfur and nitrogen is also important. Sulfur in coal is
converted primarily to H2S under the reducing conditions of gasification. Approximately 5
to 15 % of the sulfur is converted to COS, which adds some additional complexity to the
gas cleanup step but can be handled by commercially available systems. High
temperatures and low pressures favor conversion of coal-bound nitrogen to N2 while the
opposite conditions favor conversion of the coal-bound nitrogen to NH3. Small amounts
of HCN are also formed. Tars, soils, and phenols, if not destroyed, contain some of the
carbon, oxygen, nitrogen, and sulfur from the coal as more complex molecules.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 16
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

2.3.1 Texaco Coal Gasification Process

General

Typical synthesis gas compositions are shown for various feedstocks in

Table 2-2(11). Because the gasifier operates at elevated temperatures in a highly
reducing atmosphere, oxides of sulfur and nitrogen are not present.

All ranks of coals, petroleum cokes and coal liquefaction residues may be
gasified by the Texaco Gasification Process. Table 2-3(11) lists some types of
feedstocks gasified at Texaco's TGP Pilot Plants in Montebello, California. The
Ube Ammonia Coal Gasification Plant in Ube City, Japan, imports coal and coke
as feedstock and has demonstrated commercial flexibility on a wide variety of
solid feeds as shown in Table 2-4(11).

Commercial applications of the Texaco Gasification Process for solid

carbonaceous feedstocks were the direct result of over forty years of experience
with partial oxidation using gaseous and liquid feeds. Results are supported by
the construction and operation of a series of pilot demonstration and commercial
plants, some of which are listed in Table 2-5(11). The data obtained from these
units provide the basis for commercial plant designs.

Texaco Gasification Power Systems (TGPS)

Additional information regarding the Texaco Gasification Process material on the

Texaco Gasification is provided below.

Figures 2-12(11) and 2-13(11) depict the Texaco Gasification Power Systems
(TGPS) in the quench and full heat recovery mode. TGPS can operate either in
the syngas cooler or in the quench gasification configuration. Feedstock
includes coal, petroleum coke, orimulsion, heavy oil and wastes.

Three basic gasification-combined-cycle plant configurations are described in this

section(12). The major difference among the designs is the level of heat recovery
from the gas immediately downstream of the gasifier. The three designs are
radiant plus convective design, radiant only design and total quench design.

These three design configurations significantly influence the overall heat

integration of the plant, particularly with respect to high-pressure steam
generation. The impacts on the performance of each plant design are
summarized in Table 2-6 for a 59 oF ambient temperature. Performance
estimates for a nominal 500 MW subcritical coal-fired steam plant with limestone
slurry flue gas desulfurization (based on data from the EPRI Technical
Assessment Guide P-2410-SR) are also provided.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 17
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-12

QUENCH DESIGN

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 18
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Table 2-2

SYNGAS PRODUCTION FROM VARIOUS COAL FEEDSTOCKS

COAL
FEED TYPE PITTSB. NO. 8 FRENCH UTAH GERMAN S. AFRICAN
Feedstock Dry Anal, wt%
Carbon 74.16 78.08 68.21 73.93 65.60
Hydrogen 5.15 5.26 4.78 4.65 3.51
Nitrogen 1.18 0.85 1.22 1.50 1.53
Sulfur 3.27 0.47 0.37 1.08 0.87
Oxygen 6.70 8.23 15.69 5.85 7.79
Ash 9.54 7.11 9.73 13.01 20.70
Higher Heating Value
Btu/lb 13,600 14,000 11,800 13,200 11,200
Kcal/kg 7,540 7,780 6,570 7,330 6,220
Product Composition, mol %
Carbon Monoxide 39.95 37.36 30.88 39.46 36.53
Hydrogen 30.78 29.26 26.71 29.33 26.01
Carbon Dioxide 11.43 13.30 15.91 12.59 15.67
Water 16.43 19.43 25.67 17.47 20.82
Methane 0.04 0.16 0.22 0.25 0.02
Nitrogen & Argon 0.49 0.37 0.50 0.60 0.68
Carbonyl Sulfide 0.88 0.12 0.11 0.30 0.27

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 19
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Table 2-3

EXAMPLES OF GASIFIER FEEDSTOCKS AT THE TEXACO MONTEBELLO PILOT PLANTS

COAL PETROLEUM COKE COAL LIQUEFACTION RESIDUE OTHER

Anthracite Fluid Solvent Refined Coal Residue (SRC I & II) Lurgi tar/oil
Semi-anthracite Delayed H-Coal Residue Sewage sludge
Bituminous Calcined Exxon Donor Solvent (EDS) Residue Waste oils
Sub-bituminous Fluid coke from tar sands bitumen
Lignite

Table 2-4

UBE AMMONIA PLANT

FEED: Australian Coal

Chinese Coal
South African Coal
Canadian Coal
Colombian Coal
Petroleum Coke
CAPACITY: 1,650 tons of coal per day
PRODUCT: Ammonia/Urea
BY-PRODUCTS: Sulfur - Commodity sales
Slag - To cement plant
CO2 - To bottling plant

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 20
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Table 2-5

TGP PLANTS SUMMARY

COAL
OWNER TYPE LOCATION CAPACITY START-UP HEAT RECOVERY PRODUCT
Texaco Inc. Pilot California 15 TPD 1973 Direct Quench R&D
Texaco Inc. Pilot California 15 TPD 1978 D.Q./Gas Cooler R&D
Texaco Inc. Pilot California 15-50TPD 1981 Direct Quench R&D
Tennessee-Eastman Commercial Tennessee 90 TPD X 2 1983/1991 Direct Quench Acetic Anhydride
Cool Water Commercial California 1,000 TPD 1984 Gas Cooler Electric Power
Ube Ammonia Commercial Japan 1,650 TPD 1984 Direct Quench Ammonia
SAR Commercial Germany 800 TPD 1986 D.Q./Gas Cooler Oxo-Chemical/Hydrogen
Lunan Commercial China 400 TPD 1992 Direct Quench Ammonia
Shougang Commercial China 1,100 TPD 1994 Gas Cooler Fuel Gas
Weihe Commercial China 1,650 TPD 1996 Direct Quench Ammonia
Shanghai Commercial China 1,100 TPD 1996 Gas Cooler Town Gas/Chemicals
Tampa Electric Commercial Florida 2,000 TPD 1997 Radiant & Convective Electric Power

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 21
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Table 2-6

PERFORMANCE SUMMARY OF PLANTS WITH DIFFERENT CONFIGURATION

Texaco-Based IGCC Power Plants(a) Coal-Fired Steam

Radiant Plus Radiant Total Plant
Convective Design Only Design Quench Design
Illinois No. 6 Coal Feed Rate, TPD (dry) 4,984 5,318 5,318 4,627
Sulfur Removal, % 95 95 95 90
Sulfur Dioxide Emissions, lbs/106 Btu 0.28 0.28 0.28 0.8
(b)
NOx Emissions, ppmv (dry) 94 15 15(b) ~300(c)
Nox Emissions, lb/106 Btu 0.13 (b)(d)
0.04 (b)(d)
0.04(b)(d) 0.60(c)
Gas Turbine Power, MW 407 451 451 --
Steam Turbine Power, MW 273 242 213 531
Internal Power Consumption, MW 91 93 93 31
Net Plant Output, MW 589 600 571 500
Net Heat Rate, Btu/kWhr 9,009 9,436 9,920 9,853

Notes:
(a) Rated at 59 oF Ambient.
(b) GE Estimates; 15 % O2 Ref. Heat rate corrected based on Gas Turbine Combustor Performance on Synthetic Fuels, Vol. 2, p. 5-2. Palo
Alto, California: Electric Power Research Institute, June 1981, API623.
(c) Based on EPRI Report No. PE-1865, May 1981.
(d) Converted to different units by the Electric Power Research Institute.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 22
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

1.0
2.0
2.1
2.2
2.3
2.3.1

The net heat rate increases approximately by 5 % in going from the Radiant Plus
Convective to the Radiant Only Design and another 5 % in going from the
Radiant Only to the Total Quench Design. These reductions in efficiency are
primarily attributable to the reduction in high-pressure steam generation. The
effects on efficiency would be even more pronounced if it were not for the fact
that a large amount of the energy not recovered via high-pressure steam
generation is used downstream to add moisture to the fuel gas through the gas
saturator.

Water vapor must be introduced into the gas turbine combustors, along with the
fuel gas, to control the formation of NOx. Rather than consuming steam for this
duty, these plant designs utilize low-level heat to directly humidify the fuel gas via
a saturator. More low-level heat is available in the Radiant Only and Total
Quench Designs than in the Radiant Plus Convective Design, and this heat is
employed to provide fuel gas saturation in excess of that required to control
emissions.

This extra saturation increases gas turbine power by 11 % over that for the
Radiant Only and Total Quench Designs. This partially offsets the substantial
reduction in steam turbine power from the reduced generation of high-pressure
steam in the syngas coolers in the Radiant Plus Convective Design.

Although plant efficiency decreases as the amount of high-level heat recovery is

reduced, a capital cost savings results due to the removal of the expensive
syngas coolers.

Design Configurations

Three Texaco-based gasification-combined-cycle plant configurations are shown

in Figure 2-14.

In all three plant designs, coal is mixed with water and pulverized in a wet
grinding mill, producing a pumpable coal/water slurry containing 62-66 wt%
solids. High-pressure charge pumps transfer the coal/water slurry from holding
tanks to the burner of the Texaco gasifier.

The coal gasification operation requires a feed stream of 95 % pure gaseous

oxygen which is compressed to burner pressure.

The coal/water slurry and oxidant are fed to the gasifier, which is an open,
refractory-lined chamber. In the gasifier, the coal is partially oxidized at high
temperature and pressure, yielding a raw gas composed primarily of hydrogen,
carbon monoxide, carbon dioxide, and water. This raw syngas also contains
entrained molten slag and soot particles. Immediately upon exiting the gasifier,
the syngas is cooled and/or quenched via one of the three heat recovery
schemes shown in Figure 2-14. All of these diagrams are conceptual and do not
necessarily reflect actual configurations used.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 23
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-14

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 24
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Radiant Plus Convective Design

In this design, the raw gas is first cooled in an open radiant heat transfer heat
exchanger. High-pressure steam is generated in tubes built into the heat transfer
surface at the perimeter of the cylindrical gas flow zone. At the bottom of the
radiant syngas cooler, slag drops into a water quench pool where it is cooled
prior to removal from the vessels for disposal. Gas leaves the radiant cooler at a
temperature of approximately 1,500 oF and flows through a transfer duct to a
convective heat exchanger.

In the convective syngas cooler, the gas flows across boiler tube banks that are
specially designed to accommodate the entrained particles that are too fine to
drop out in the bottom of the radiant cooler. High-pressure steam is generated in
these tubes. The raw gas leaves this convective cooler at a temperature of
650 oF and flows to the gas scrubbing unit.

There is one radiant and one convective cooler per gasifier.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 25
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Radiant Only Design

In this design, coal is gasified and the hot raw gas is introduced into the same
radiant heat exchanger described above. The raw gas is similarly cooled by
generating high-pressure steam. At the bottom of the radiant cooler in this case,
however, both the raw gas and the slag are quenched in water and cooled. Slag
is removed from the exchanger vessel for disposal. The water-saturated raw gas
at a temperature of approximately 400 oF flows to the gas scrubbing unit.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 26
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Total Quench Design

As in the previous two cases, coal is gasified at high temperature and pressure,
producing a raw gas containing entrained, molten slag and soot particles. In this
design, however, the high-temperature raw gas cooling and high-pressure steam
generation are eliminated. Instead, hot raw gas is introduced directly into a
water quench chamber and cooled. Slag is removed from the chamber for
disposal. The water-saturated raw gas at a temperature of approximately 430 oF
flows to the gas scrubbing unit.

These three design configurations for the Texaco gasification and

high-temperature gas cooling section significantly influence the overall heat
integration of the plant. As less heat is recovered in high-temperature gas
cooling, the stream of raw gas to scrubbing contains more energy, which must
eventually be recovered usefully in a service.

After leaving the waste heat recovery section, the cooled and/or quenched raw
gas is washed with water to remove any fine particles of soot and slag that were
not collected in the previous cooling/quenching operation.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 27
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Scrubbed raw gas is further cooled in the low-temperature gas cooling section.
Nearly all of the energy removed from the raw gas is utilized to generate
low-pressure steam, to heat feed water, or as a source of heat for fuel gas
moisturizing. The magnitude of the energy recovered in this section depends on
the heat recovery in the high-temperature raw gas cooling section. The radiant
Plus Convective Design will have much less low-temperature energy recovery
than will the Total Quench Design.

Cooled raw gas is fed to the sulfur removal system, where it is washed with
either a chemical or a physical solvent to selectively remove sulfur compounds
produced in the gasifier. These sulfur compounds are converted into elemental
sulfur in a Claus sulfur plant. Clean, dry, medium-Btu fuel gas leaving the sulfur
removal system is, at this point, suitable for use as gas turbine fuel.

Water vapor is introduced into the combustors of the gas turbines, along with the
fuel gas, to control the formation of NOx. Rather than consuming steam to
control the gas turbine emissions, these plant designs utilize low-level heat to
directly humidify the clean fuel gas in the fuel gas saturator section.

Gasification, High-Temperature Gas Cooling, Particulate Removal and Ash

Removal

Based on EPRI report, listed as Reference 13, Overall Block Flow Diagram,
837305-TC-RC-1-1 (P. 28) shows the process schematically.

Process Flow Diagram 837305-TC-RC-20-1(13) (P. 29) shows the gasification,

high-temperature gas cooling, particulate removal and ash dewatering steps.
The material balance presented on the drawings applies to a 20 oF ambient case;
for other ambient/supplemental-firing subcases, scale factors are provided.

Four operating gasification trains, each with a nominal capacity of 1,575 tpd (as
received) coal are provided, along with one train of ash handling equipment.
Proprietary sections of the Texaco coal gasification process that contain several
equipment items are represented on the flow diagram by 20-ME-1 and
20-1-ME-2.

Coal slurry from the storage tanks is delivered to the gasifier burners by the
slurry charge pumps 20-1-P-1. The coal slurry combines with oxygen at the
burner. The burner, which is oriented downward from the top head of the
gasifier, contains cooling coils through which tempered water is circulated. The
gasifier 20-1-R-1 operates at a pressure of 600 psig and a temperature range of
2,400 oF to 2,600 oF. This temperature range is sufficiently above the Illinois
No. 6 ash flow point to ensure free flowing molten slag. A portion of the coal
feed burns, providing heat for the endothermic gasification reactions. The
hydrogen and carbon in coal react to form CO, CO2, H2 and a little CH4, while the
sulfur is converted to H2S and COS. Most of the nitrogen in the coal is released
as free nitrogen (N2) with the remainder converted to NH3 and trace amount of
cyanide.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 28
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 29
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 30
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

High-Temperature Gas Cooling

Hot crude gas with molten ash at 2,400 oF to 2,600 oF enters the radiant syngas
cooler 20-1-B-1 where high-pressure (1,545 psia) saturated steam is generated
by recovery of high-level sensible heat. The radiant syngas cooler is of vertical
downflow design with steam coils on the inside walls. The gas leaving the
radiant syngas cooler at approximately 1,500 oF is subsequently cooled to 650 oF
in the vertical convective syngas cooler where additional high-pressure (1,545
psia) saturated steam is generated in tubes.

The radiant and convective syngas coolers adopted in this manual are based on
Fluor's evaluation of several manufacturers' quotes. Among the differences in
the syngas cooler configuration between different manufacturers is the method of
cleaning the boiler tubes, namely soot-blowing with recycle gas, or with high
pressure nitrogen. Although the flow diagrams do not show the equipment
(recycle compressor and surge vessel) required for soot-blowing using recycle
gas, the heat and material balance and sizing of downstream equipment
(scrubber and gas cooling units) do, however, allow for soot-blowing.

Particulate Removal (Gas Scrubbing Unit)

The cooled particulate-bearing raw gas enters the scrubbing unit 20-1-ME-2,
where contact with recycled process condensate and makeup water results in
virtually complete removal of solids. The solids-free raw gas then flows to the
gas cooling unit.

Ash Removal

During gasification, most of the mineral matter in the coal converts to molten slag
and subsequently falls into a water quench at the bottom of the radiant waste
heat boiler vessel, producing an ash slurry. Solids entrained in the gas are
captured in the gas scrubbing unit 20-1-ME-2. The ash slurry from the quench
vessel and the solids slurry produced in the gas scrubbing unit flow to the ash
dewatering unit 20-ME-1. Some heat recovery from the hot slurry occurs in
20-ME-1 whereby makeup water to the scrubber and slurry preparation (Unit 10)
are preheated. The cooled slurry is then clarified and filtered to yield an ash
cake and water. The ash cake, estimated to contain approximately 50 wt%
water, is transported to the battery limits for ultimate disposal. Part of the
reclaimed process water is recycled to the slag quench and gas scrubber. The
remainder of the process water is purged to a proprietary Texaco water treating
process. The purge serves to avoid chloride buildup and to remove slag and
soot particles, dissolved metals, formates, sulfides and ammonia. The treated
water is used as slurry water in slurry preparation (Unit 10).

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 31
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Low-Temperature Gas Cooling and Fuel Gas Saturation

Process flow diagram TC-RC-21/25-1(13) shows the process scheme for

low-temperature raw gas cooling and saturation of clean fuel gas for the 20 oF
ambient case under the Radiant Plus Convective Design. The following is a
general description of the process.

The fuel gas saturator (Unit 25) and the low-temperature gas cooling section
(Unit 21) are described together because of the close heat integration of the two
units. Two parallel operating trains are provided in each unit. No spare trains
are included in either unit.

Solids-free raw gas from the particulate scrubbing unit is first cooled in 21-1-E-1
by heat exchange to the circulating saturator water. Further cooling of the raw
gas is accomplished in 21-1-E-2 by heating vacuum condensate and makeup
water from the steam, BFW, and condensate system (Unit 30). Condensate
water from the bottom heads of both of these vertical exchangers flows to the
condensate collection drum 21-1-V-2. The raw gas, now at 130 oF, is cooled to
105 oF in the trim cooler 21-1-E-3 against cooling water. The cooled gas is
separated from the condensate in the knockout drum 21-1-V-1 and is directed to
the acid gas removal unit. If necessary, a fraction of the cooled gas can be
compressed and recycled to Unit 20 for soot blowing in the syngas coolers. The
heat and material balance basis used for equipment design in the gas cooling
section allows for this recycle soot blower gas.

The clean fuel gas from the acid gas removal is essentially free of moisture and
enters the bottom of the saturator vessel 25-1-V-1. The saturator is a vertical
column with sieve trays where the cold fuel gas flowing upward is contacted
countercurrently with hot water flowing downward. Transfer of moisture and heat
takes place from the liquid stream to the gas stream. The fuel gas leaves the top
of the column at 325-350 oF with a moisture content of 25-30 wt% and, after
being reheated to 570 oF in the gasification unit, flows to the gas turbine in
Unit 50. In the 59 oF and 88 oF ambient cases with supplemental firing, the
supplemental fuel gas bypasses the saturator and is fired directly in the gas
turbine exhaust duct. Only the fuel gas consumed in the gas turbine is saturated
with moisture and reheated.

To maintain the required liquid-to-gas ratio in the saturator, a large quantity of

water is circulated. The necessary heat is supplied by heating the circulating
water in the exchangers 25-1-E-1 and 21-1-E-1 in parallel. The latter was
described under gas cooling. In the former, a slipstream of high-pressure BFW
from the HRSG economizer is used to heat the circulating water. The heated
water combines with a sidestream of BFW from the HRSG and the hot water
flows to the top of the saturator. The BFW sidestream serves as a makeup
stream to compensate for the moisture transferred to the fuel gas and also as a
purge stream taken from the bottom of the saturator to avoid buildup of any
solids.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 32
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 33
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Commercial Status

All the equipment in the gas cooling unit is commercially available and proven in
the Cool Water project. To obtain the design moisture content and temperature
of the fuel gas, precise control of BFW temperature and circulation should be
maintained, and this is believed to be within the realm of proven process control.
A fuel gas saturator has been installed at the Cool Water plant where it has
operated for five years.

Acid Gas Removal

The function of the acid gas removal system is the selective removal of hydrogen
sulfide (H2S) from the syngas. Refer to Fluor Daniel Process Manual, Selective
Acid Gas Removal Processes.

Selective removal of sulfur compounds is preferred as the energy of the CO2 can
be recovered in the turbine without exceeding limits on sulfur emissions. Thus
on H2S removal system which minimizes CO2 capture is preferred.

Sulfur Recovery

Refer to Process Manual-Volume 17, Sulfur Plant Design for details.

2.3.2 Shell Coal Gasification Process

Coal gasification by Shell uses dry coal feed. The coal is mixed with steam and
oxygen as it enters the gasifier through a feed gun. The reaction takes place at
the tip of the feed burner or gun. The burners face the center of the gasifier
180 degrees apart. These gasifiers can have either two or four burners in each
gasifier. The gasifier can be characterized as a high temperature, entrained
type. The operating temperature in the gasifier is between 2,500 - 3,000 oF and
operating pressure is around 450 psig. The types of coal used as feedstock may
be lignite, subbituminous or bituminous coal. Carbon conversion is in excess of
99 %. A simplified process flow diagram showing Shell coal gasification process
is given in Figure 2-15.

Gasification/Gas Quench and High-Temperature Gas Cooling

The Shell coal gasification process (SCGP) is proprietary in nature. Overall

Block Flow Diagram 846404-1-1-1 (11) shows the process schematically.

Pressurized coal is transported by nitrogen and metered to the gasifier where,

along with oxygen and steam, it enters the gasifier through opposed burners.
The overall gasification reaction is exothermic, and the gasifier consists of an
outer pressure vessel and an inner, water-cooled membrane wall. The gasifier
wall temperature is controlled by circulating boiler feedwater through the
membrane wall to generate saturated steam for subsequent superheating in the
syngas cooler. The membrane wall encloses the gasification zone from which
two outlets are provided: one, at the bottom for the removal of slag; the other, at
the top for the removal of hot raw gas.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 34
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-15

SHELL COAL GASIFICATION PROCESS

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 35
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

The majority of the ash contained in the feed coal leaves the gasification zone in
the form of molten slag. The high gasifier temperature ensures that the molten
slag flows freely down the membrane wall into a water-filled compartment at the
bottom of the gasifier. As the molten slag comes in contact with the water bath,
the slag solidifies into dense, glassy granules. The slag granules fall into a
collecting vessel located beneath the slag bath from which the slag is transferred
to the Slag Handling Unit.

The temperature of the slag bath is controlled by circulating the water through an
external cooler. A portion of the circulated slag bath water is withdrawn to
control the buildup of suspended solids and is directed to the Wet Particulate
Removal System.

The hot raw product gas leaving the reaction zone is quenched with recycle gas
to convert the entrained molten slag to ash-like solid material (flyslag) prior to
entering the syngas cooler. The quenched gases pass from the gasifier to the
syngas cooler through a connecting duct which is also lined with a water-cooled
membrane wall for steam generation.

The syngas cooler recovers high-level heat from the quenched raw gas by
generating superheated high-pressure steam at 1,505 psia and 1,007 oF. Each
syngas cooler consists of superheater, evaporator and economizer sections. A
steam drum and boiler feedwater circulation pumps are provided for each
gasifier/syngas cooler train.

Slag Handling

Slag from the water-filled collection vessel at the bottom of each gasifier is
transferred to a pair of lock hoppers which are connected in parallel, operating on
a timed cycle. During filling, the slag is washed with clean makeup water to
remove entrained gas and any surface impurities. The makeup water flows from
the lock hoppers to the slag bath system in the gasifier. After filling, the lock
hopper is depressurized and the slag is fed to the dewatering vessel. The
dewatering vessel is equipped with an inclined screw to lift the settled solids off
the bottom of the vessel and deposit them on a belt conveyor for delivery to
off-site storage and disposal facilities.

Dry and Wet Particulate Removal

Following high-temperature gas cooling, the cooled raw gas is directed to fly-slag
separators in which the bulk of the entrained flyslag is removed from the raw
product gas. The dry, separated flyslag is removed from the bottom of the
separator vessel and pneumatically conveyed to a Flyslag Handling and Storage
Unit.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 36
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Raw gases from each separator train are combined and sent to the wet
scrubbing unit to further reduce residual flyslag to a level of less than 1 ppm.
Other minor contaminants such as soluble alkali salts are also removed to low
levels. To control the concentration of contaminants in the water after scrubbing,
makeup water is continually added from the Gas Treating and Cooling section to
the wet scrubbing system and a blowdown stream is withdrawn to the Sour
Water Stripping Unit.

Gas Treating and Gas Cooling

The washed raw gas from wet scrubbing is routed to a catalytic hydrolyzer to
convert the minor nitrogen contaminant (hydrogen cyanide) to ammonia, and
carbonyl sulfide to hydrogen sulfide. The gas is heated to the desired reaction
temperature by medium pressure (225 psia) steam before entering the
hydrolyzer. The hydrolyzer effluent is subsequently cooled to 100 oF by
consecutive heat exchange with recycle process condensate, steam turbine
vacuum condensate and cooling water.

At the inlet to the water-cooled exchanger, makeup water to the system is mixed
with the partially cooled effluent to remove ammonia from the gas stream. The
two phase mixture is separated in a knockout drum from which condensate is
recycled to wet scrubbing and cooled scrubbed gas stream is directed to the Acid
Gas Removal unit for final cleanup.

All equipment is commercially available, except the HCN/COS conversion

catalyst which will be tested at the Shell Buggenum plant in Holland in 1994.

Sour Water Stripping

Process water purged from the Wet Particulate Removal System and
condensate from the Tail Gas Treating System are fed to the Sour Water
Stripper (SWS) for removal of ammonia and hydrogen sulfide. Details designing
sour water stripping systems can be found in Fluor Process Manual Volume 35,
Sour Water Stripper.

Acid Gas Removal

Refer to Fluor Daniel Process Manual, Selective Acid Gas Removal Processes.

Sulfur Recovery

Refer to Process Manual Volume 17, Sulfur Plant Design for details.

Fuel Gas Saturation

The fuel gas saturation system is similar as Section 2.3.1.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 37
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

2.3.3 DOW/DESTEC Coal Gasification Process

Destec technology for coal gasification plant is developed to accept lignite,

subbituminous and bituminous coal as the feedstock. The gasifier is designed to
operate at high temperature between 1,900 - 2,600 oF and at 450 psia pressure.
The gasifier is characterized by a two stage, entrained slurry design. Carbon
conversion is in excess of 99 %.

A simplified process flow diagram showing major process streams around the
Destec gasifier is illustrated in Figure 2-16.

Based on EPRI report, listed as Reference 16, Overall Block Flow Diagram
459700-DOW-BC-1-1 shows the process schematically.

Gasification, High Temperature Gas Cooling and Particulate Removal

Process Flow Diagram DOW-BC-42-1(16) shows the gasification, high

temperature gas cooling, particulate removal, and slag dewatering steps.
Proprietary sections of the Dow coal gasification process such as slag
dewatering and char handling are represented on the flow diagram by blocks.
Two operating gasification trains, each with a nominal capacity of 3,515 tpd(16) (as
received) coal are provided.

Gasification

Coal slurry from storage tanks is preheated by low and medium pressure steam
heaters 42-1-E-100, 101, 110 and 111, and then fed to the gasifier burners. The
gasifier 42-1-R-120 consists of two stages, the first with two burners and the
second with one. Approximately 80 % of the total slurry is fed to the first stage,
and the balance goes to the second stage. 95 % pure oxygen is fed to the first
stage burners only to support the gasification reaction.

The first stage is operated in a slagging mode at a temperature of about

2,600 oF. This temperature is sufficiently above the coal ash fluid point to ensure
free flowing molten slag. The molten slag flows downwards into the quench
chamber of the gasifier where it is contacted with water and solidified.
Approximately 99.9 % of the carbon in the coal fed to the first stage is gasified.
The product gas from the first stage flows upwards to the second stage of the
gasifier. The slag is crushed by grinders and sent to the slag dewatering system.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 38
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 39
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 40
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Figure 2-16

DESTEC COAL GASIFICATION PROCESS

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 41
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

The hot gas coming from the first stage contacts the coal slurry entering the
second stage, and provides the heat for gasification. The gas exits the second
stage at 1,900 oF, the maximum temperature allowed in the waste heat boiler,
depending upon coal characteristics, cooling to 1,900 oF may also be assisted by
cold gas recycle. Three events occur in the second stage of the gasifier. All of
the coal slurry water evaporates, coal devolatilization products form, and carbon
reacts with the syngas components in a reducing environment. Approximately
80 % of the carbon fed to the second stage is gasified and the overall (first and
second stage combined) carbon conversion per pass is about 96 %. The two
stage gasifier works very well on low rank coals because it uses high level waste
heat to vaporize a large fraction of the volatiles present in the reactive coal
slurry, instead of using oxygen to oxidize this part of the carbon to CO2 to supply
the heat.

The hot crude gas exiting the gasifier along with the char (carbon containing ash
particles) is directed to the cyclone 42-1-CY-120. The char is separated from the
gas and recycled to the first stage of the gasifier. By recycling the unreacted
carbon, the overall carbon conversion reaches 99.6 wt%. This value will vary
between 99.5 and 99.9 % depending on coal reactivity. Also, by delaying a
portion of the carbon oxidation reaction until after the water and volatiles have
been removed, the oxygen requirement is reduced.

High-Temperature Gas Cooling

The crude gas now enters the syngas cooler where high pressure (1,620 psia)
saturated steam is generated by recovering the sensible heat in the gas. The
syngas cooler consists of three sections: the evaporator 42-1-E-150, the
economizer 42-1-E-151 and the steam drum 42-1-D-150. Boiler feedwater is fed
to the economizer section, heated and sent to the steam drum. Additional
preheated make-up boiler feedwater is fed to the steam drum. A superheater
may also be provided in the event that steam is generated at pressure lower than
1,620 psia.

Particulate Removal

The gas stream enters the soot scrubber knockout drum 42-1-C-160 along with
slag quench water. The drum bottoms, made up of slag and soot slurry, is
recycled through the char handling system; recovered solids are recycled to
gasification via the slurry blending tank in System 10. The solids-free raw gas is
directed to the low temperature gas cooling section.

Slag Handling

During gasification, all of the mineral matter in the coal converts to molten slag
and subsequently falls into a water quench at the bottom of the gasifier vessel.
Crushers at the bottom of the gasifier convert the slag and water into a slurry. In
the slag dewatering system the slurry is concentrated to a 75 % solids cake,
which is transported to the battery limits for ultimate disposal or possible sale.
The water separated from the slag is cooled and then recycled to the gasifier
quench vessel and sent to the soot scrubber drum.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 42
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

Low-Temperature Gas Cooling and Fuel Gas Saturation

Process Flow Diagram DOW-51/55-1(16) shows the process scheme for

low-temperature raw gas cooling and saturation of clean fuel gas. The fuel gas
saturator (System 55) and the low-temperature gas cooling section (System 51)
are described together because of the close heat integration of the two units.
Two parallel operating trains are provided.

Solids-free raw gas from the syngas scrubber is cooled in a series of four heat
exchangers. The low-pressure steam boiler, 42-1-E-160 cools the gas and
produces 65 psia steam from condensate. The gas then proceeds to the primary
reboiler 42-1-E-161 for the H2S stripper where it is cooled further. The third
exchanger, the saturator heater 42-1-E-162, takes the cool saturator bottoms
steam, heats it, and returns the water to the saturator top. The condensate
heater 42-1-E-163 heats the low-pressure turbine condensate before returning it
to the HRSG, System 60. Condensate water from the stationary heads of these
exchangers drains to the sour water drum 51-1-D-160. The H2S absorber cooler
42-1-E-164 uses air to cool the syngas to a final temperature of 120 oF. The gas
is separated from the condensate in knockout drum 51-1-D-164, and directed to
the acid gas removal unit.

The clean, moisture-free fuel gas returns from acid gas removal and enters the
bottom of the saturator vessel 51-1-C-171. The gas saturation process is similar
to Section 2.3.1.

The fuel gas is moisturized for two important reasons. First, the moisture inhibits
the formation of NOx compounds during combustion in the gas turbine. Second,
moisturization of the fuel provides additional motive fluid flow for the gas turbine,
which increases the turbine power output.

The condensate collected in the sour water drum 51-1-D-160 is directed to the
process water treating unit (System 76).

Other heat recovery schemes have been proposed in other studies if Dow
gasification is performed by Fluor Daniel.

Acid Gas Removal

The acid gas removal system is similar to Section 2.3.1.

Sulfur Recovery

Refer to Process Manual Volume 17, Sulfur Plant Design for details.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 44
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

2.3.4 Other Coal Gasification Processes

Other coal gasification processes are as follows:

The Combustion Engineering Coal-Gasification Process

British Gas/Lurgi Slagging Gasifier
The KRW Coal-Gasification Process
The Fluidized-Bed Coal Gasification Process (Winkler Type)
Lurgi Coal Gasification (Moving-Bed Gasifier)
Foster Wheeler-Stoic Process
The Saarberg/Otto Coal-Gasification Process
The Westinghouse Coal-Gasification Process
The Kilngas System
U-Gas Fluid-Bed Gasifier
Others

Detailed process descriptions for the above processes are not included in this
manual because they are beyond the scope of this work.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 2.0
SYNGAS GENERATION
PAGE 45
PROCESS MANUAL MANUFACTURING TECHNIQUES
DATE 08-94

2.4 REFERENCES

1. European patent Application number: 89300704.7

2. U. S. Patent Application number: 4666680

3. Hydrogen Production by Enhanced Heat Transfer Reformer (EHTR), Air

Products and Chemicals, S.I. Wang and N.M. Patel, AIChE 1988.

4. Mossel Bay Onshore Project, Process Comparison of the three synthesis gas
production bids, Dr. C.L. Render, Sastech, 1988. (Confidential Report).

5. CAR: A New Reformer Technology, H.D. Marsch and N. Thiagarajan, UHDE

Gmbh, Dortmund, West Germany.

6. European Patent Application number: 87310717.1.

7. Choose optimal syngas route, R.V. Schneider III and J. R. Le Blanc, the M.W.
Kellogg Company, Hydrocarbon Processing, March 1992.

8. U.S. Patent number: 39558951.

9. A Heat-Exchanger Type Steam Reformer for Ammonia Production. T. Miyasugi

et al., Chiyoda Chemical Engineering & Construction Co., Yokohama, Japan,
CEP July 1984.

10. "The Texaco Synthesis Gas Generation Process" - Texaco Development

Corporation, January 1984.

11. "Texaco Gasification Process for Solid Feed Stocks" - Texaco Development
Corporation, 1993.

12. Copyright © 1984. Electric Power Research Institute. EPRI AP-3486. Cost and
Performance for Commercial Applications of Texaco Based Gasification -
Combined Cycle Plants. Volume 1: Summary and Discussion of Results.
Reprinted with Permission.

13. Copyright © 1984. Electric Power Research Institute. EPRI AP-3486. Cost and
Performance for Commercial Applications of Texaco-Based
Gasification-Combined-Cycle Plants. Volume 2: Detail Designs. Reprinted with
Permission.

14. Copyright © 1989. Electric Power Research Institute. EPRI GS-6126. Florida
Power and Light Company's Study of Shell-Based GCC Power Plants.
Reprinted with Permission.

15. Copyright © 1983. Electric Power Research Institute. EPRI AP-3129.

Shell-Based Gasification-Combined-Cycle Power Plant Evaluations. Reprinted
with Permission.

16. Copyright © 1989. Electric Power Research institute. EPRI GS-6318.

Evaluation of a Dow-Based Gasification-Combined Cycle Plant Using Low-Rank
Coals. Reprinted with Permission.

17. Copyright © 1990. Electric Power Research Institute. EPRI GS-6904.

Evaluation of a Dow-Based Gasification-Combined Cycle Plant Using Bituminous
Coal. Reprinted with Permission.

K:\WRK090\037\345\MANUALS\SYNGAS\009-02A.SAM-05/09/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 1 of 20
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

1.0
2.0

3.0 PROCESS CALCULATIONS

3.1 SIMULATIONS WITH GPC

General

The Gas Process Calculator, 10780, hereafter referred to as GPC, is a PC based

computer program that models most unit operations involving gas streams, liquid water
and steam. GPC will compute the heat and material balances of most unit operations
involved in the production of synthesis gas from a variety of feedstocks. GPC can
perform calculations for steam methane reformer and for partial oxidation reactors.

Fluor Daniel management will not guarantee a gasification reactor based on GPC or any
other internal tools. Process guarantees will be issued only on the basis of a licensor
basic engineering package for at least key parts of the plant. GPC can be very useful for
process analysis, waste best recovery studies and configurational studies.

The program runs on an interactive basis or it can be operated in a batch mode using a
P001 input file. Reference is made to the 10780 GPC USER'S GUIDE of July 1992
which summarizes the capabilities of GPC and includes calculation examples.

The following steps are normally followed in the design of any synthesis gas plant:

1. Develop the initial draft of the Process Flow Diagram (PFD).

2. Identify unit operations and assume (initial) temperature/pressure profiles as a

starting point.

3. Establish the heat and material balances for all chemical reactors.

4. Calculate the process duties of the streams to be heated and the streams to be
cooled.

5. Calculate and summarize the performance and power/utility requirements for all
the other operations, i.e., gas purification unit(s), compressors, pumps, fans,
steam/gas turbines, fired equipment, separators, etc.

6. Layout the heat recovery system and develop the steam balance.

7. Revise the initial PFD and temperature/pressure profiles.

The process engineer can use GPC to calculate the following reactors:

Tubular Reforming of Natural Gas up to Heavy Naphthas.

Auto Thermal Reforming of Natural Gas up to Heavy Naphthas.
Partial Oxidation of Natural Gas up to Heavy Oils and Residues.
Coal/Coke Gasification.
COS Hydrolysis.
CO Shift reaction.
Methanation.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

A wealth of information is openly available regarding Tubular Reforming, COS

Hydrolysis, CO Shift Reaction and Methanation. Unfortunately, published data
concerning Auto Thermal Reforming, Partial Oxidation and Coal Gasification is scarce
and, if available, usually incomplete, or proprietary and confidential.

An attempt was made to "curve-fit" the Texaco Synthesis Gas Generation Process
(TSGGP) based on data contained in the Texaco brochure for liquid feeds, and other
data (normal operating conditions and maximum operating conditions) for a particular
type of coal. Feed inlet temperature and operating pressure were assumed to closely
match the feed rates, dry product gas compositions and cold gas efficiencies. The
resultant thermodynamic data, i.e., reactor flame temperatures and equilibrium
temperatures for methane and carbon monoxide, were determined by GPC. Refer to
Table 3-1 and Figure 3-1 for a summary of the results.

The following trends are observed for the thermodynamic conditions at the reactor exits
(Figure 3-1 shows related data points connected for clarity). Flame temperatures range
between 2,300 oF and 2,700 oF maximum. The CO equilibrium temperature is 1,900 oF
for coal, averages 2,150 oF for liquids, and equals 1,950 oF for natural gas. The CH4
equilibrium temperature is 2,100 oF for coal, averages 2,150 oF for liquids, and is about
2,350 oF for natural gas. However, anomalies were detected for Naphtha and Vacuum
Resid. Also, discrepancies in the published data for H-Oil have been corrected.
Therefore, all information presented in Table 3-1 should only be used as a
guideline and as a starting point for further development. The starting values
shown in Table 3-2 may be used for initial estimates (normal operating conditions).

GPC can also assist the engineer to generate duty specifications for the following
equipment:

Compressors
Expanders
Steam/Gas Turbines
Gas/Water Separators
Heat Exchangers
Combustion Equipment
Deaerator/Flash Drum
Desuperheater
Saturator

3.1.1 GPC Tubular Reformer Calculations

Both the Hydrogen Manual and the GPC User's Guide contain elaborate
information and include examples for calculating Tubular Reformers using Option
20. Note that Option 22 should be used for defining the data of the liquid
feedstocks and the process steam stream must be recalled with Option 5 before
running reformer calculations using Option 20. Do not use the Dulong formula
for the heating value of liquid feedstocks; the API method is recommended.
Assumed temperature approaches to equilibrium are 35 - 50 oF for Reforming
reaction and 0 oF Shift reaction.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 3
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Figure 3-1

TEXACO POX FEEDSTOCKS

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 4
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-1

SUMMARY OF TSGGP SIMULATIONS

16 Jun 93 NOC
H-Oil 0 API Kentucky #9 DOC Kentucky #9
Feed Type Natural Gas 64 API Naphtha 9.6 API Fuel Oil 9.6 API Fuel Oil 4.3 API VacResid Bottoms Asphalt LF Coal LF Coal
Composition (wt%) Texaco FD Texaco FD Texaco FD Texaco FD Texaco FD Texaco FD Texaco FD Texaco FD Texaco FD
Published & Simulated Publ Sim Publ Sim Publ Sim Publ Sim Publ Sim Publ Sim Publ Sim Publ Sim Publ Sim
Carbon 73.40 73.40 83.80 83.80 87.20 87.20 87.20 87.59 83.80 84.07 84.33 84.58 84.60 84.86 67.0 62.89 64.5 57.64
Hydrogen 22.76 22.76 16.20 16.20 9.90 9.90 9.90 9.60 9.65 9.49 8.89 8.75 8.91 8.76 4.8 4.29 4.1 3.38
Nitrogen 3.08 3.08 -- -- 0.70 0.70 0.70 0.68 0.31 0.30 1.12 1.10 0.68 0.67 1.2 1.07 1.0 0.82
Sulfur -- -- -- -- 1.40 1.40 1.40 1.36 6.2 6.10 5.56 5.47 4.90 4.82 3.8 3.47 5.1 4.20
Oxygen 0.76 0.76 -- -- 0.80 0.80 0.80 0.78 0.00 0.00 0.00 0.00 0.78 0.77 6.5 5.8 4.8 3.96
Ash -- -- -- -- 0.00 0.00 0.00 0.00 0.04 0.04 0.10 0.10 0.13 0.13 16.7 22.47 20.5 30.01
C/H Ratio (kg/kg) 3.22 3.22 5.17 5.17 8.81 8.81 8.81 9.13 8.68 8.86 9.49 9.66 9.49 9.69 13.96 14.68 15.73 17.05
Temperature ( oF) -- 550 -- 550 -- 700 -- 700 -- 700 -- 700 -- 700 -- 100 -- 100
Pressure (psia) -- 700 -- 700 -- 700 -- 700 -- 700 -- 700 -- 700 -- 700 -- 700
Higher Heating Value
kcal/kg 12572 12572 11278 11278 10111 10111 10111 10096 9628 9620 9491 9485 9500 9492 6882 6390 6528 5733
Btu/lb 22630 22630 20300 20300 18200 18200 18200 18172 17330 17316 17084 17072 17099 17086 12388 11501 11751 10320
Rate/MNm3 Dry Prod. Gas REACTOR REACTOR REACTOR Ovrll Reactor Ovrll Reactor Ovrll Reactor Ovrll Reactor Ovrll Reactor Ovrll Reactor
Hydrocarbon (kg) 276.8 278.1 313.6 314.5 340.9 337.9 329.8 340.2 346.1 352.6 390.0 366.3 357.6 363.6 495.6 555.4 522.9 635.3
Steam(kg) -- -- 78.3 78.5 156.8 155.5 186.9 187.0 173.1 173.3 158.7 161.4 182.0 181.9 312.3 312.5 422.9 424.1
Oxygen (NM3) 248.0 248.0 239.0 276.8 240.0 238 241.0 241.1 245.0 245.4 418.0 269.0 268.0 269.2 317.9 322.6 341.2 341.7
Carbon (kg) 0.0 0.0 1.9 1.8 10.8 10.6 0.0 10.4 0.0 5.9 0.0 6.2 0.0 6.2 0.4 17.5 0.8 29.3
% Carbon Conversion 100.0 100.0 99.3 99.3 96.4 96.4 100.0 96.5 100.0 98.0 100.0 98.0 100.0 98.0 99.9 95 99.7 92.0
% Carbon Recycle NONE NONE NONE -- 100.0 -- 100.0 -- 100.0 -- 100 -- 97.7 -- 97.1
% Ash Recycle NONE NONE NONE -- NONE -- NONE -- NONE -- NONE -- 34.0 -- 43.7
Temperature Steam ( oF) -- 550 -- 550 -- 550 -- 550 -- 550 -- 550 -- 550 -- -- -- --
Temperature Oxygen ( oF) -- 250 -- 250 -- 250 -- 250 -- 250 -- 250 -- 250 -- 250 -- 250
Pressure Reactor(psia) -- 615 -- 615 -- 615 -- 615 -- 615 -- 615 -- 615 -- 615 -- 615
Dry Product Gas (mol %)
Carbon Monoxide 35.0 35.2 45.3 45.4 48.5 48.2 47.5 47.5 48.3 48.3 51.2 51.3 49.3 49.7 43.8 44.0 38.9 39.1
Hydrogen 61.1 60.9 51.2 51.0 45.9 46.0 45.8 45.6 44.2 44.1 41.4 41.5 42.1 41.7 36.2 36.2 34.9 34.8
Carbon Dioxide 2.6 2.6 2.7 2.7 4.6 4.7 5.7 5.8 5.2 5.3 5.3 5.1 6.5 6.6 17.8 17.7 23.2 23.2
Methane 0.3 0.3 0.7 0.7 0.2 0.2 0.5 0.5 0.6 0.6 0.3 0.3 0.4 0.4 0.2 0.2 0.5 0.5
Nitrogen plus Argon 1.0 0.9 0.1 0.1 0.7 0.7 0.2 0.3 0.2 0.2 0.4 0.5 0.4 0.3 0.6 0.6 0.6 0.6
Hydrogen Sulfide -- -- -- -- 0.1 0.3 0.3 0.3 1.4 1.4 1.3 1.3 1.2 1.1 1.3 1.3 1.8 1.8
Carbonyl Sulfide -- -- -- -- -- 0.0 -- 0.0 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
02 Consumption
Nm3(O2) / MNm3(H2+CO) 258 258 248 287 254 253 258 259 265 266 451 290 293 295 397 403 462 463
Cold Gas Efficiency:
HHV(H2+CO) / HHV(FEED) 83.9 83.6 82.8 82.6 83.1 83.6 84.9 84.8 84.2 84.1 75.9 82.4 81.6 81.7 71.2 71.2 65.6 65.6
H2/CO Ratio (mol/mol) 1.75 1.73 1.13 1.12 0.95 0.96 0.96 0.96 0.92 0.91 0.81 0.81 0.85 0.84 0.83 0.82 0.89 0.89
Thermodynamics:
o
Tflame( F) -- 2636 -- 2546 -- 2535 -- 2608 -- 2300 -- 2705 -- 2694 -- 2700 -- 2700
Tch4( oF) -- 2358 -- 2096 -- 2305 -- 2113 -- 2090 -- 2165 -- 2090 -- 2110 -- 1900
Tco( oF) -- 1934 -- 3046 -- 2035 -- 2068 -- 2120 -- 2360 -- 2215 -- 1900 -- 1900

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 5
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-2

THERMODYNAMIC DATA FOR TSGGP

Thermodynamics Type of Feedstock

NAT. GAS LIQUID SOLID

TFLAME ( oF) 2,650 2,550 2,700

TCH4 ( oF) 2,350 2,150 2,100

TCO ( oF) 1,950 2,150 1,900

H2O/Feed (lb/lb) None 0.25 - 0.55 0.615

O2/Feed (lb/lb)(a) 1.28 1.10 0.916

Notes:
(a) Adjusted to match flame temperature

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 6
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

API Method for Heating Value of Liquid Fuels

The following method is recommended for distillates,

Qu = 8,505.4 + 846.81K + 114.92G + 0.12186G2 - 9.9510KG + 91.23 (% H) (1)

Where:

Qu = uncorrected gross heat of combustion, Btu/lb

K = Watson characterization factor
G = API gravity
%H = wt% of hydrogen in the fuel

For residues,

Qu = 47.47G + 16,690 + 91.23 (% H) (2)

For all liquid fuels,

∆ Hu = Qu - 91.23 (% H) (3)

Where ∆ Hu = uncorrected net heat of combustion, Btu/lb

Q = Qu - 0.01Qu (% H2O + % Ash + % S) + 40.5 (% S) (4)

Where:

Q = corrected gross heat of combustion, Btu/lb

% H2O = wt% of water in the fuel
% Ash = wt% of ash in the fuel
%S = wt% of sulfur in the fuel

∆H = ∆ Hu - 0.01∆ Hu (% H2O + % Ash + % S) + 40.5 (% S) - 10.53 (% H2O)

Where ∆ H = corrected net heat of combustion, Btu/lb (5)

The wt% of hydrogen in the fuel can be calculated from the carbon-to-hydrogen weight
ratio, C/H, with the following equation:

100.0 − (% H 2 O + % Ash + %S)

%H =
C/H + 1.0

Procedure
Step 1: Obtain the Watson Characterization factor and the carbon-to-hydrogen weight
ratio.
Step 2: Calculate the percent by weight of hydrogen from Equation (6).
Step 3: Calculate the uncorrected gross and net heats of combustion from Equations (1)
and (3), if the fuel is a distillate, or from Equations (2) and (3), if the fuel is a
residue.
Step 4: Using data from an analysis of the fuel, find the corrected gross and net heats of
combustion from Equations (4) and (5).

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 7
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

3.1.2 GPC Auto Thermal Reformer Calculations

Essentially identical to Tubular Reformer calculations with the exception that this
reactor operates under adiabatic conditions. Therefore, the reactor exit
temperature in Option 20 should not be specified but calculated. Note that
Option 22 must be used for liquid feedstocks and the oxidant stream (including or
excluding steam) must be recalled with Option 5 before running Option 20. Do
not use the Dulong formula for the heating value of liquid feedstocks; the API
method is recommended.

3.1.3 GPC Partial Oxidation Calculations

These are identical to Auto Thermal Reformer calculations with some exceptions.
Since this reactor does not contain catalyst, the equilibrium temperature
approaches can only empirically be determined. Also, a special procedure is
followed to incorporate carbon recycle in the overall calculation scheme. If
carbon conversion is unknown, a 98 % carbon conversion may be assumed. It
also calculates the enthalpy loss due to unconverted carbon and slag. Radiation
heat loss from the gasifier should be accounted for.

3.1.4 GPC Coal Gasification Calculations

The GPC calculations are identical to Partial Oxidation calculations, except the
Dulong formula can be used to calculate the heating value of coal on a moisture
free basis, and the coal is fed to the reactor as a slurry without steam injection.
Therefore, the weight % water should be included in Option 22 (usually
35-40 %). The simulations shown in Table 3-1 for coal include carbon recycle for
most of the cases summarized.

3.1.5 GPC COS Hydrolysis/CO Shift/Methanation Calculations

Option 20 is used to simulate the performance of these reactors. The Hydrogen

Manual provides additional design information on these catalytic systems.

3.1.6 Other GPC Equipment Calculations

Refer to the GPC User's Guide.

3.1.7 Overall Plant Simulations Using the P00l File

Once proficiency is obtained in running all the various Options of the GPC main
menu, the designer may want to avoid manual repetition and link the individual
unit operations together in one flowsheet simulation program which can be run
batchwise.

The following sample problem is offered for practice:

SAMPLE PROBLEM #1

Gasification of Coal

This sample problem provides a method to estimate the performance of a

Texaco gasifier for a specific coal.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 8
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

The following information is given:

Coal Feed Rate (Dry Basis) 1,020 lb/hr

Ultimate Analysis (wt%) for Pittsburgh No. 8 Coal

Carbon 74.67
Hydrogen 5.05
Oxygen 6.57
Nitrogen 1.16
Sulfur 3.20
Ash 9.36

The following data is assumed:

Oxygen Purity 99.5 mol %

Argon (Balance)
0.5 mol %
Temperature 250 oF
Pressure 700 psia

Gasifier Pressure 615 psia

Carbon Conversion 98 %
Coal Slurry Temperature 100 oF

Based on Table 3-2 and the given coal feed rate, the following (normalized) data
is initially assumed:

Water 627.3 lb/hr

Oxygen 934 lb/hr

From Figure 3.1-1:

CH4 approach to equilibrium = 2,700 - 2,100 = 600 oF

CO approach to equilibrium = 2,700 - 1,900 = 800 oF

STRATEGY

1. Use Option 1 to input 934 lb/hr = 29.19 lbmol/hr of O2 and 0.15 lbmol/hr
of Ar at 250 oF and 700 psia in Stream 1. Use Option 22 to input the
ultimate coal feed analysis, input the feed conditions, and calculate the
energy loss.

2. Create a P001 file based on the following sequence. Recall Stream 1

and run Option-20 to calculate the initial gasifier exit temperature. Adjust
Stream 1 (Oxygen) with Option 7 and iterate with Option 25 to achieve a
gasifier exit temperature of 2,700 oF. Display and print the stream
summary.

3. Run the P001 file.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 9
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

INPUT

Note: All data between brackets reflect input.

1. Following is a stream summary output (Option 10) after the Oxygen data
has been declared with Option 1 and stored under Stream 1 with
Option 3.

Stream No. 1. 0. 0. 0.
Compound Mol/Hr
O2 <29.19> 0.00 0.00 0.00
Ar <0.15> 0.00 0.00 0.00

Total Mols 29.34 0.00 0.00 0.00

Total Lbs# 939.84 0.00 0.00 0.00
Temp oF <250.00> 0.00 0.00 0.00
Psia <700.00> 0.00 0.00 0.00
MM-Btu/hr 0.04 0.00 0.00 0.00
Water-MPH 0.00 0.00 0.00 0.00

2. Following is a "screen dump" of Option 22 after the input has been

declared.

Enter the following data for a solid or liquid feed coal/oil data

Ultimate analysis - wt% of dry coal or oil

Carbon? <74.67>
Hydrogen? <5.05>
Oxygen <6.57>
Nitrogen? <1.16>
Sulfur? <3.20>
Ash? <9.36>
Total wt% water? <38.1>
Feed rate - dry lb/hr ? <1020>
Carbon conversion % ? <98>
Dry coal/oil HHV - Btu/lb (enter 0 for Dulong <0>
Formula)?
Fuel temp. F ? <100>
Fuel bound nitrogen to NH3 % ? <0>
Dry coal HHV 13,613.03 Btu/LB

Limestone data
Calcium to sulfur feed mole ratio ? <0>

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 10
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Coal/Oil Feed Data

Feed Dry Adj Dry Dry LB/HR Atoms/Hr
wt% wt% (WET)

Carbon 74.67 74.67 761.634 62.14211

Hydrogen 5.05 5.05 51.51 120.8059
Oxygen 6.57 6.57 67.014 39.03833
Nitrogen 1.16 1.16 11.832 0.8447386
Sulfur 3.2 3.2 32.64 1.017964
Ash 9.35 9.35 95.37 0

Total 100 100 1,020 223.849

Total water in feed - lb/hr 627.819

Carbon lost 15.23268 lb/hr
Calcium carbonate entering = 0 lb/hr at 1 wt% purity
Sulfur captured = 0 mol/hr

Total Fuel & Limestone Energy In

MM Btu/hr

HHV 13.88529
Fuel Sens. 0.0102
Lime Sens. 0
Water Sens. 2.511276E-02
Total 13.9206

For a reactor heat loss estimate enter the ash temp F

Otherwise enter zero ? <2,600>
Enter radiation & misc. losses MM Btu/hr ? <0>
Losses - MM Btu/hr

Carbon HHV 0.2145828

Carbon Sens. 1.238112E-02
CaS HHV 0
Slag/Ash 6.298325E-02
Reactor Loss 0

Total 0.2899462(a)

This is for info only and not automatically used

elsewhere.

Note:
(a) Use this data in the P001 file.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 11
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

3. Create and run the following P001 file.

ENTRY NO. DATA MENU CONTROL STEP

1 5 Recall a stream
2 1
3 7 Multiply this stream flow by a constant
4 1
5 3 Save this stream
6 2
7 20 Cos hyd. Shift, methanation, reform or pox reactors
8 6
9 - 0.29
10 0
11 615
12 0
13 - 800
14 - 600
15 3 Save this stream
16 3
17 25 Recycle to match stream temp, press, flow or K
18 4
19 3
20 23
21 2,700
22 0.1
23 1
24 1
25 9 Display stream summary
26 10 Print stream summary
27 19 End

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 12
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

OUTPUT

Note: The following stream summary is automatically displayed on the monitor

and printed. Data between brackets indicate input.

Stream No. 1 2 3 0
Compound Mol/Hr

H2 0.00 0.00 36.38 0.00

N2 0.00 0.00 0.42 0.00
O2 <29.19> 30.61 0.00 0.00
CO 0.00 0.00 46.52 0.00
CO2 0.00 0.00 15.37 0.00
H2S 0.00 0.00 0.90 0.00
COS 0.00 0.00 0.11 0.00
C1 0.00 0.00 0.13 0.00
H2O 0.00 0.00 22.73 0.00
Ar <0.15> 0.15 0.15 0.00
Total Mols 29.33 30.77 122.71 0.00
Total lbs 939.84 985.79 2,520.32 0.00
Temp oF <250.00> <250.00> <2,700.00> 0.00
Psia <700.00> <700.00> <615.00> 0.00
MM-Btu/hr 0.04 0.00 13.67 0.00
Water-MPH 0.00 0.00 0.00 0.00

Note: Another eight solid feedstocks were selected for similar simulations to
obtain a summary of the gasifier performance estimate. The results are
summarized in Table 3-3.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 13
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-3

SUMMARY OF GPC SIMULATIONS

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 14
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

3.2 OTHER SIMULATORS

General

Other commercial simulators capable of doing flowsheet simulations for syngas plants
are:

ASPEN
HYSIM
PRO/II
Q131

Most of these simulators are in general specifically written for refinery unit operations and
require development of special "add-on" routines for chemical reactors. An in-depth
evaluation of these simulators for syngas applications has not been performed.
Reportedly, some Fluor Daniel engineers are in the process of developing flowsheet
simulations for hydrogen plants based on HYSIM and ASPEN. The results are yet to be
published.

An alternative approach to flow simulations is to use a spreadsheet. The following

section describes a generic hydrogen plant program written for Lotus 123 and uses no
macros.

3.2.1 H2PSA1 Program

This spreadsheet needs about 250K RAM. The process configuration includes
shift conversion and a PSA Unit. The program calculates complete heat and
material balances and estimates the feed, fuel and major utility consumptions
and costs based on user specified values of selected variables. Also, preliminary
sizing is provided for the steam reformer furnace and other reactors. Thermal
rating of the steam reformer is based on data from furnaces with 4" ID radiant
tubes at 9" center to center spacing.

The reforming and shift reaction equilibrium constants are identical to GPC.
However, the enthalpy data may differ and the steam dewpoint routine is not as
sophisticated as GPC. Therefore, the main objective of this program is to quickly
determine optimum conditions first before rigorous calculations are conducted. It
may also prove handy for sensitivity analyses.

The program summarizes critical process data on one page, which is divided in
three panels. Explanations are provided separately, one page for each panel. A
typical hydrogen plant flowsheet is also attached for clarity.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 15
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Instructions

Load the program on the hard disk and retrieve with Lotus 123.

Change any of the input variables (as indicated by <) within the
spreadsheet boundaries indicated by "stars", i.e., *******.

Push the F9 key till the convergence criteria are met (Cell C14 = 1).

Major changes causing recalculation of the chemical equilibrium may take up to

50 iterations running for about two minutes on an Everex 386/16 computer. The
default value is presently set at 10 iterations since smaller changes not affecting
the reforming equilibrium take less iterations.

Notes:

(1) It is recommended to check the heat exchanger temperature profiles

prior to further process design efforts. This requires all heat exchangers
be laid out manually using the data supplied by the program.

(2) This program was originally written in Metric units and has only partially
been converted to English units.

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 16
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

FLOW DIAGRAM OF A TYPICAL H2 PLANT EXCLUDING AIR PREHEAT

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 17
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-3

SUMMARY (OVERALL) OF H2PSA1 SIMULATION

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 18
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-4

SUMMARY (LEFT PANEL) OF H2PSA1 SIMULATION

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 19
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-5

SUMMARY (MIDDLE PANEL) OF H2SA1 SIMULATION

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 3.0
SYNGAS GENERATION
PAGE 20
PROCESS MANUAL PROCESS CALCULATIONS
DATE 08-94

Table 3-6

SUMMARY (RIGHT PANEL) OF H2PSA1 SIMULATION

K:\WRK090\037\345\MANUALS\SYNGAS\009-03.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 1 of 14
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

1.0
2.0
3.0

4.0 LICENSOR/VENDOR INTERFACES

4.1 INTRODUCTION

Process and mechanical design of process units such as gasification, acid gas removal
and the process waste water treating require licensor data specific to the project
requirements. To properly design the unit, accurate and complete licensor packages are
essential. This also implies that the licensors need to be provided with all the required
information such as site conditions, feed data and product requirements.

Attachment 4-1 shows a sample questionnaire for major design items that need to be
considered for a gasification-based power plant. The collection of all the data referenced
in this questionnaire provides the process design basis. This design basis document can
be used for providing the relevant plant data to licensors/vendors when requesting
specific performance data of their system.

4.2 LICENSOR/VENDOR CONTACTS

Table 4-1 provides a summary of the various licensor contacts.

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Attachment 4-1

GASIFICATION PLANT DESIGN BASIS QUESTIONNAIRE

(For IGCC plants - for produciton syngas based products (methanol et al) a much more
elaborate questionaire would be needed).

1. Design Site and Weather Conditions

Location

Design dry bulb temperature

Design wet bulb temperature
Design maximum temperature
Design minimum temperature

Elevation

Design wind speed

Design rainfall

Wind, rainfall, seismic, soil, water table data. Is air monitoring data available?

Ambient Air Composition (humidity, dust, etc.)

Site accessibility for construction equipment, plant equipment, coal delivery.

2. Design Coal/Coke

Type of coal: Sub-bituminous, bituminous or lignite.

Type of coke: Fluid or delayed

Ultimate Analysis
(wt% dry basis)
Ash
Carbon
Hydrogen
Oxygen
Chloride
Nitrogen
Sulfur

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 3
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Attachment 4-1 (Continued)

GASIFICATION PLANT DESIGN BASIS QUESTIONNAIRE

HHV (Btu/lb, dry basis)

LHV (Btu/lb, dry basis)
Moisture (wt%, as received)
Ash Fluid Temperatures (oF, reducing atmosphere)
Chloride Content, max
Equilibrium Moisture Content, wt%
Slurriability data
Hardgrove Grindability Index
Coal size distribution (as delivered)
Gasifier feed coal size distribution
Concentration of metals such as Fe, Ni, Cr, Mg V, Sc and others (for petroleum coke)

3. Environmental Considerations

Land: Slag Disposal (coarse slag and fine slag)

Water: Wastewater (required treatment for disposal)

Air: Required sulfur removal, required NOx concentration in exhaust

gas to atmosphere.

Noise Standards: 85 decibels at 3 ft (federal limit).

All equipment with excessive noise will be provided with

enclosures. Any local requirements?

Safety: Hazards & Operability (HAZOP)

4. Economic Criteria

Labor: Union/non-union
Wage rates
Efficiency
Work week

Procurement: worldwide or local?

Start-up date
Utility requirements during construction
Contingency

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 4
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Attachment 4-1 (Continued)

GASIFICATION PLANT DESIGN BASIS QUESTIONNAIRE

5. General

Facility - New
- Stand alone
- Phased construction
- Integrated vs. non-integrated
- Cogeneration requirements
- Black start capability

Availability, reliability and plant on-stream requirements

Target Heat Rate

Minimum Power Output required

Load following vs. load leveling

Repowering vs. refueling scenarios

6. Shipping, Receiving & Storage

Coal: Delivery mode

Dead storage capacity
Live storage capacity
uncovered storage would require rainwater collection and fines recovery
system.
covered storage would require greater capital cost.

7. Oil (if required)

Delivery mode

Storage capacity

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 5
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Attachment 4-1 (Continued)

GASIFICATION PLANT DESIGN BASIS QUESTIONNAIRE

8. Coal Grinding/Slurrying

Grinding method (dry vs. slurry)

Design grinding mesh size

Slurry data (if applicable)

concentration
viscosity
storage
pump type
additives

9. Coal Gasification

Type
Heat Recovery Mode: Radiant + Convective
Radiant Only
Quench

Operating Temperature
Operating Pressure
Oxygen Purity
Design H2S/COS ratio
Ammonia yield
Slag density
Refractory type
Soot blowing rate
Carbonyls/cyanides/formate production
Material balance

10. Ash/Slag Handling

Type of ash settling system

Slag disposal or sale as aggregate
Wastewater treatment and disposal

11. Gas Cooling

Syngas temperature
Maximum Ammonia concentration in syngas to acid gas removal
Need for COS Hydrolysis

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 6
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Attachment 4-1 (Continued)

GASIFICATION PLANT DESIGN BASIS QUESTIONNAIRE

12. Acid Gas Removal

Solvent
Required Sulfur Removal
Removal requirements for Carbonyls, Cyanides, Formates from Syngas

13. Saturator

Required moisture in syngas for NOx control

Saturator Packing type

14. Gas Turbine

Type
Fuels: Syngas, back-up fuel
Nitrogen injection capability
Air Extraction Provision
Minimum LHV
Turndown requirements

15. Scot/Claus

Required sulfur recovery rate

Solvent
Scot Reactor Temperature
Scot Reactor Catalyst
Claus Reactor type
Molten sulfur or solidified sulfur product
O2 blown/enriched air/air - if ammonia is present in the Claus feed gas, O2 blown Claus
will be considered.
Burner fuel

16. Incinerator

Operating status: standby/continuous

Flame temperature
Air requirements
Burner fuel

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 7
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Attachment 4-1 (Continued)

GASIFICATION PLANT DESIGN BASIS QUESTIONNAIRE

17. HRSG

By pass duct
Superheat/reheat steam conditions
Duct firing
Selective catalytic reduction
Carbon monoxide catalyst
Sulfuric acid dew point considerations

18. Steam Turbine

Preinvestment for IGCC mode

19. Utility Requirements

Oxygen - Purity
- Compressor type
- Driver type - motor or steam turbine or gas turbine
- Availability

Nitrogen - Gas turbine injection, syngas cooler soot-blowing

Air (plant, instrument)

Electricity requirements

Plant Fuel Gas

Water - raw
- potable
- boiler feed
- cooling
- demineralized

Steam - high pressure

- medium pressure
- low pressure

Cooling methods
- cooling tower
- pond cooling
- sea water cooling

If cooling tower is used, design cycle of concentration.

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 8
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

Gasification Texaco Manager of Licensing (914) 253-7915 (914) 253-7744
Coal Gasification
2000 Westchester Ave.
White Plains, NY 10650
Shell Commercial Development (713) 241-5507 (713) 241-6781
Synthetic Manager
Fuels Inc. Two Shell Plaza
Houston, TX 77252-2099
Destec Market Development Manager (713) 735-4358 (713) 735-4393
Coal Gasification
2500 City West Blvd., Suite 150
Houston, TX 77210-4411
Reforming KTI Development Manager (909) 592-4455 (909) 592-3399
650 Cienga Ave.
San Dimas, CA 91773-2933
Uhde Uhde GmbH 49-6196-205-0 49-6196-205-420
Friedreich Uhde Strasse 2
Postfach 1529
D-6232 Bad Soden/Taunus Germany
(Or)
West Coast Representative (714) 646-5533 (714) 646-1129
Dr. Hans Linhardt
1221 W. Coast Hwy. #204
Newport Beach, CA 92663

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 9
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1 (Continued)

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

Foster General Manager (908) 730-4000 (908) 730-5315
Wheeler Perryville Corporation Park
Clinton, NJ 08809
Or
304 Invernes Way South, Ste 475 (303) 790-7764 (303) 790-7757
Inglewood, CO 80112
Selas 5 Sentry Parkway East (215) 834-0300 (215) 834-0473
Blue Bell, PA 19422
Syngas Cooler MAN-GHH General Manager (412) 364-3700 (412) 364-2329
5700 Corporate Drive, 8th Floor
Pittsburgh, PA 15237
Or
Department Manager 49-208-692-2053 49-208-692-2037
Gas Technologies
Bahnhofstrasse 66
D-4200 Oberhausen 11
Germany
Steinmuller General Manager, Process Equip. 49-2261-852651 49-2261-852999
GmbH 5270 Gummersbach 1
Germany
Borsig GmbH Central Sales Manager Dept. KXV 49-30-43010 49-30-43012236
Berliner Strasse 27-33
1000 Berlin 27, Germany
Deutsche Head of Process Dept. 49-208-833-3489
Babcock Dulsburger Strasse 375
D-4200 Oberhausen 1
Germany

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 10
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1 (Continued)

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

Air Separation Air Products Art Smith (215) 581-6628 (215) 481-6489
Manager
Allentown, PA 18195-1501
Airco Business Manager (908) 464-8100 (914) 771-6545
575 Mountain Avenue
Murray Hill, NJ 07974
Lotepro Corp Manager, Project Development (914) 747-3500 (914) 747-3422
115 Stevens Ave.
Valhalla, New York NY 10595
Prax Air Business Manager (203) 794-5599
39, Old Ridgebury Road
Danbury, CT 06817
Air Liquide Business Manager (510) 977-6500 (510) 977-6840
Or 2121T N. California Blvd.
Liquid Air Walnut Creek, CA 94596
(Or)
West Coast Representative (714) 646-5533 (714) 646-1129
Dr. Hans Linhardt
1221 W. Coast Hwy. #204
Newport Beach, CA 92663
Acid Gas Removal DOW Gas/Spec Technology Group (415) 930-6400 (415) 746-5256
1676 N. California Blvd.
Suite 400
Walnut Creek, CA 94596

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 11
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1 (Continued)

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

Union 6700 E. Pacific Coast Hwy. (800) 225-5784 (213) 493-2852
Carbide Suite 240
(Ucarsol or P.O. Box 22691
Selexol) Long Beach, CA 90801
Linde AG Gas Plants Section 49-89 74 45 26 42 49-89 74 45 49 31
Dr. Carl VonLinde Strasse 6-14
8023 Hoellriegelskreuth near Munich,
Germany
Or
Lotepro Corp Manager, Project Development (914) 747-3500 (914) 747-3422
(in U.S.A.) 115 Stevens Avenue
Valhalla, New York NY 10595
Sulfur Recovery LURGI Lurgi Ol Gas Chemie GmbH 49-69-5808-1530 49-69-5808-2645
Gas and Synthesis Technology
Division
Lurgi-Allee 5,
P.O. Box 111231
D-6000 Frankfurt am Main
Germany
Comprimo C/O Goar Allison & Assoc. Inc. (903) 561-8456 (903) 561-7692
P.O. Box 131390
Tyler, Texas 74713
TPA, Inc. President (214) 669-2908 (214) 234-1954
TPA, Inc.
9101 LBJ Freeway, LB 2
Dallas, TX 75243

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 12
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1 (Continued)

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

Methanol Lotepro Corp. Manager, Project Development (914) 747-3500 (914) 747-3422
Linde AG 115 Stevens Ave.
Valhalla, New York NY 10595
Or
Gas Plants Section 49-89 74 45 26 42 49-89 74 45 49 31
Dr. Carl Von Linde Strasse 6-14
8023 Hoellriegelskreuth near Munich,
Germany
LURGI Lurgi Ol Gas Chemie GmbH 49-69-5808-1530 49-69-5808-2645
Gas and Synthesis Technology
Division
Lurgi-Allee 5, P.O. Box 111231
D-6000 Frankfurt am Main
Germany
ICI ICI, Licensing Dept 642 553601 642 533366
P.O. Box 1
Katalco Billingham Cleveland
TS23 1LB England
Or
Area Manager (312) 838-3200 (312) 838-3243
4099 West 71st Street
Chicago, IL 60629

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 13
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1 (Continued)

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

Uhde Uhde GmbH 49-6196-205-0 49-6196-205-420
Methanol Friedreich Uhde Strasse 2
(Continued) Postfach 1529
D-6232 Bad Soden/Taunus
Germany
(Or)
West Coast Representative (714) 646-5533 (714) 646-1129
Dr. Hans Linhardt
1221 W. Coast Hwy. #204
Newport Beach, CA 92663
Mitsubishi Mitsubishi Gas Chemical Co. 025-259-6578 025-259-6931
3500 Matsuhama-Cho,
Nigata-city, 550-31
Japan
Shift Converter United United Catalysts, Inc. (502) 634-7248 (502) 639-3732
Catalysts P.O. Box 32370 Or
Louisville, KY 40232 (800) 523-4151
BASF Business manager (201) 316-3000 (201) 402-7924
100-T, Cherry Hill Road
Parsippany, NJ 07054
Haldor Product Manager 45-287-8100 45-287-8494
Topsoe A/S Nymollevej 55, DK-2800 Lyngby,
Copenhagen, Denmark
(Or)
Manager of Engineering Sales (713) 480-2600 (713) 480-3371
P.O. Box 58767
Houston, TX 77258-8767

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 4.0
SYNGAS GENERATION
PAGE 14
PROCESS MANUAL LICENSOR/VENDOR INTERFACES
DATE 08-94

Table 4-1 (Continued)

SUMMARY OF LICENSOR CONTACTS

Technology Licensor Address Phone No Fax No Comments

ICI ICI, Licensing Dept. - P.O. Box 1 642-553601 642-533366
Katalco Billingham Cleveland
TS23 lLB England
(Or)
Area Manager (312) 838-3200 (312) 838-3243
4099 West 71st Street
Chicago, IL 60629
Fischer-Tropsch Shell SIPM 31-70-377-9117 31-70-377-2093
Manufacturing & Development Div.
Carel Van Bylandtlaan 30
The Hague, The Netherlands
Sasol Sastech 27-16-708-9111 27-16-708-2027
P.O. Box 1
Sasolburg 9570

K:\WRK090\037\345\MANUALS\SYNGAS\009-04.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 1 of 28
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94
1.0
2.0
3.0
4.0

5.0 EQUIPMENT CONSIDERATIONS

5.1 REFORMER

Refer also to the Process Manual Volume 27 - Hydrogen Plant Design, Sections 3.0 and
6.0.

Process Discussion

The catalyst reaction of reforming hydrocarbon with steam is highly endothermic and the
reformer process gas outlet temperature varies between 1,450 oF and 1,650 oF.
Therefore, high reformer firebox equilibrium temperatures are required, resulting in
radiant firebox efficiencies generally below 50 % on a lower heating value basis. The
combustion gas leaving the radiant firebox recovery is cooled for additional heat
recovery.

To minimize the number and length of the reformer tubes (the most expensive part of the
reformer), minimize the catalyst volume and promote the overall furnace efficiency, the
reactants are preheated to the maximum allowable level, ranging from 840 oF for naphtha
to 1,100 oF for methane. Inlet temperatures should be carefully selected to avoid
cracking of the feedstock.

Steam/hydrocarbon preheat takes about 25-30 % of radiant heat absorption, therefore

large quantities of heat remain available for waste heat recovery.

The following reactions occur over nickel catalyst:

←
CH4 + H2O → CO + 3H2 (a) (Endothermic)
→
CO + H2O ← CO2 + H2 (b) (Exothermic)

The equilibrium reaction (a) is shifted to the right by increasing the steam to carbon ratio
or the reaction temperature and shifted to the left by increasing pressure.

The operating pressure, the outlet temperature and the steam to carbon ratio are the
primary variables to be considered in the process design.

Depending on the size of the Plant, and economics, the range of the above mentioned
variables for Reformers are as follows:

- Operating pressure: up to 435 psi

- Outlet temperature: 1,450 - 1,650oF
- Steam/carbon ratio: 2.5 - 4.0

Catalyst

In general, nickel based catalysts are used to promote the reforming reactions of natural gas.

The three major parameters of reforming catalyst are:

- Activity
- Physical strength
- Stability over prolonged period

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Physical strength is as important as catalyst activity. If catalyst disintegrates as a result

of chemical changes at reforming temperatures and pressures, or due to thermal shock
occuring at Plant shutdowns or start-ups, dust will interfere with gas distribution, causing
gas flow restriction and overheating of tubes because of reduced heat transfer.

In case vaporized naphtha is used as reformer feedstock, cracking tendency due to the
presence of heavier hydrocarbons at the inlet of the reformer tube, is considerably
greater than for a natural gas feedstock. Several types of catalyst for naphtha feedstock
have been developed and have been operating satisfactorily in many plants for several
years.

One of the successful catalysts includes potash which resists carbon lay down.
However, potash has the disadvantage of migrating from the catalyst to the gas, in
particular at high temperatures. Therefore, it is deemed necessary to have two catalyst
layers in each reformer tube. The hot bottom part is filled with active non-alkaline
catalyst, the top and cooler part is filled with a low activity potash containing catalyst.

Another successful catalyst does not contain any potash and uses a magnesium oxide
base and is alkaline instead of a nickel oxide base. The advantage of this catalyst is its
reasonable activity and therefore a single catalyst for the total length of the reformer tube
can be used. However, this catalyst tends to be sensitive to steaming.

It is of importance to note, that when alkaline catalyst is used, the reformer tubes should
have no dead-end in the bottom section, where condensate can accumulate. Stress
corrosion cracking in the tube bottom may otherwise occur.

Catalyst vendors must be consulted for all reforming applications.

Reformer Radiant Firebox Design Considerations and Configuration

Considerations for an optimum reformer design are:

- Tube temperature profile must be free from peaks.

- Freedom from direct flame impingement on tubes must be assured by selection

of suitable burners.

- Horizontal distribution of heat load must be assured over the length of the
furnace by correct distribution of reactants, fuel, combustion air and flue gas.

Fluor Daniel does not design reformers but these items are important in checking furnace
vendors quotations and designs.

Available reformer furnace designs as shown schematically on Figure 5-2 can be

principally classified in four types:

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 3
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Figure 5-2

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 4
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

(1) Vertically Up-fired Furnaces

Vertically up-fired furnaces have generally three rows of burner lanes in the floor
firing upflow and between two vertical tube rows with the process stream flowing
either down or up.

(2) Side Fired Furnaces

Side fired furnaces consist of a row of tubes placed between refractory walls on
both sides. Within both refractory walls, small horizontally fired radiation burners
are installed, each covering approximately one square meter of radiant refractory
wall.

(3) Vertically Down-fired Furnaces

Vertically down-fired furnaces have two or more rows of vertical tubes with
forced draft burners firing downwards between the rows and same type of
burners firing between refractory walls and outer tube rows.

(4) Terrace Wall Furnaces

Terrace wall furnaces consist of a row of tubes placed between steeped, inclined
refractory walls on both sides, with two or three rows of burners at equally
spaced elevations over the height of the radiant firebox.

Reformer Tube Materials

The majority of past reformers have been equipped with centrifugally cast tubes made
from HK 40 material.

The composition of HK 40 is as follows:

wt%
Cr 24 - 27
Ni 19 - 22
C 0.35 - 0.45
Mn 1.75 max.
Si 1.5 max.
Mo 0.5 max.
Fe Balance

Certain proprietary alloys of the general 25 Cr 35 Ni category such as Thermalloy 63,

MO-RE 1, and Manaurite 36 X have been successfully used for design metal
temperatures around 1,830 oF. These materials are claimed to have 30 to 40 % higher
stress to rupture characteristics than HK 40 at 1,795 oF and have largely supplanted
HK-40 tubes.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 5
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

The typical composition of a 25 Cr 35 Ni alloy is as follows:

wt%
C 25 - 28
Ni 34 - 36
C 0.40 - 0.50
Mn 1.25 max.
Si 1.50 max.
Nb Additions
Fe Balance

Reformer Process Gas Inlet and Outlet Systems

In designing large reformers, it is considered imperative that inlet and outlet pigtails and
manifolds are positioned outside the radiant firebox.

The advantages of having pigtails and manifolds outside the firebox or in a separate
outlet manifold enclosure box are:

- The pigtails and manifolds are easily accessible for inspection purposes.

- The materials are only subjected to the hot process fluid on the inside and not to
higher firebox temperatures.

- In case of tube failure, tube overheating or pigtail/tube weld failure, the entire
plant need not be shut down.

Both inlet and outlet pigtails are fabricated from ductile material that enables the
pigtails to be nipped or squeezed so that flow of reactants or back flow of product
gas cannot occur. Simple tools have been developed for this nipping operation
in many plants. The reformer can be operated at nearly 100 % throughput for
several months with a number of tubes isolated.

- Catalyst tubes can be removed easily without disturbing refractory.

The inlet pigtails are generally made out of low alloy steel and are designed to absorb
horizontal expansion of inlet headers, vertical expansion of reformer tubes and self
expansion. Because of their relative high pressure drop, even distribution of feedstock
from the headers to the reformer tubes is assured.

The reformer tube exits are connected by small diameter Incoloy 800 pigtails to the outlet
manifold.

The outlet pigtails of most designs have to be long to accommodate for both vertical and
horizontal expansion of the outlet manifold as well as self expansion. The horizontal
expansion of the manifold is the most important, in particular for large reformers.

In some vertically downfired designs and the terrace wall design, through a particular
design feature, the outlet pigtails are relieved from the manifold's horizontal expansion
load, hence pigtails can be short and thus have a relatively low pressure drop.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 6
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Outlet manifolds are mostly fabricated from wrought Incoloy 800 material.

Burners and Combustion

The heat energy input system of the reformer is of major importance.

When discussing the reformer radiant box configurations, burner types have been briefly
reviewed.

The air inspiring radiant burners have considerable limitations. With the continuously
rising cost of light hydrocarbons, it is of great interest to fire lower cost liquid fuels such
as distillates or even low sulfur and metal free fuel oils.

The forced draft burners used in downfired furnaces and natural draft, and the
non-inspiring burners used in Terrace Wall furnaces can burn a wide range of gaseous
and liquid fuels.

For these burners combustion of synthesis purge gas, which may vary in composition, is
no problem.

More and more large reformer installations are equipped with combination oil and gas
burners. The first oil fired reformer dates back to 1961, but since then, many reformers
have been operating for several years successfully firing gas and oil.

The liquid fuels used have been distillates, since residual fuels usually have too high
sulfur and/or metals content, which causes an undue amount of corrosion of the 25-20 Cr
Ni catalyst tubes at temperatures in the range of 1,560-1,830 oF.

Hence, a conservative limit has been set on sulfur, vanadium and sodium concentrations.

In general, it is recommended that sulfur content in fuel should not be more than 0.75
wt% and total vanadium, magnesium and sodium content should be below 10 ppm.

It is of interest to note that on a very large Terrace Wall furnace installation, a heavy gas
oil distillate containing 1.6-1.8 wt% of sulfur was burned for a period longer than 2 years
without any noticeable corrosion on the outside of the tubes or refractories. However,
metal content of this gas oil was below 2 ppm.

If liquid fuels are to be fired, other aspects of reformer design should be considered:

- Although it is entirely possible to operate at 10 % excess air, it is desirable to

design for 15 % excess air as a safety factor in achieving good combustion and
flame stability at different then design loads.

- In particular the terrace wall design incorporates a very high proportion of hot
refractory surface and therefore the combustion mechanism is extremely efficient
and very little soot is formed. It is desirable, however, to incorporate installation
of sootblowing equipment in the convection bank. In the event a plant upset
affects atomizing steam or fuel oil preheat, formed soot can be removed.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 7
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

- On-stream removal of oil guns for cleaning should be easy. Therefore,

automatic steam purge and safety interlocks are to be provided.

- Since oil flames are highly luminous, observation doors for radiant pyrometer
temperature reading of catalyst tubes should be located so that flames are not
interfering when measuring tube temperatures.

One way to increase furnace efficiency is to use combustion air preheat at the expense
of increased NOx emissions.

Combustion air preheat can be accomplished and has been used in two ways.

- The use of air preheaters on the reformer hot flue gas to recover the maximum
amount of heat before venting to the atmosphere.

- The use of heat contained in a gas turbine exhaust gas stream.

Several large reformer installations utilize gas turbines for driving natural gas or
synthesis gas compressors. The gas turbines provide a readily available supply
of oxygen-rich gas at pressures sufficiently high for distribution to a duct system
feeding the reformer burners.

Gas turbine exhaust varies in temperatures between 840 and 930 oF with an
oxygen content of approximately 17 wt% and is available at pressures between
125 to 250 mm of water column.

Reformer Flue Gas Waste Heat Recovery

A considerable amount of heat is available in the flue gas after it leaves the reformer
radiant section.

In order to optimize waste heat recovery, as many as six or seven independent heating
services can be incorporated in the reformer convection bank. Typical examples are
process steam, hydrocarbon preheat, hydrocarbon feed preheat, one or more pressure
levels of steam generation, steam superheat and boiler feedwater preheat.

These services are essentially uncontrolled and will fluctuate in load as the function of
the level of operation of the radiant section.

A flue gas temperature profile must be established in order to arrange all these services
and to take advantage of the optimum mean temperature difference.

One very important factor is that these furnaces do not start-up at 100 % of load design
conditions. Experience shows that in particular for large Plants, the reformer furnace
may operate as low as 40 % of design capacity for extended periods of time. With this in
view, the convection bank may have to be laid out to avoid exceeding design outlet
temperatures and tube failures at low load conditions.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 8
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

It is usually desirable to place some steam generating capacity in the high flue gas
temperature area to take some of the shock effect of black body radiant heat transfer out
of the flue gas, thereby stabilizing the outlet temperatures of the other convection
services over a wide range of operating loads.

In some cases, process heat requirements for the various services in the convection
section exceed the available heat in the flue gas coming from the radiant section. Hence
auxiliary firing facilities may be installed up-stream of the convection section to increase
the heat content of the flue gas.

The modified flue gas temperature profile obtained with auxiliary firing should be
examined carefully in order to provide proper protection to those coils in the convection
section which will normally have no flow or reduced flows during start-up or low load
conditions.

In connection with the convection section design, the flue gas evacuation system is to be
considered. This can be accomplished either through the use of induced draft fans or by
a natural draft stack.

Down-fired furnaces are difficult to design without the use of induced draft fans. Terrace
wall furnaces have been built and are operating with natural draft stacks. However, with
efficiencies close to 90 % and hence flue gas temperatures between 355-390 oF, natural
draft stacks become very high and expensive. Furthermore, it should be emphasized
that negative pressure must exist in all parts of the furnace under all operating
conditions. With the large number of openings through which the catalyst tube
extensions must pass, the very high radiant flue gas temperatures and positive pressure
in the firebox becomes quickly catastrophic.

For above reasons, induced draft fans for flue gas evacuation are usually preferred. All
modern large size reformers are provided with induced draft fans for flue gas removal.
Where air preheat is employed, forced draft fans are normally employed.

Steam drums associated with the flue gas heat recovery must be adequately sized, not
only to provide of the high quality steam required by the Plant, but also to provide at least
a 3 to 5 minutes continuous supply of steam at full design load from low water level to
empty drum conditions in case of failure of make-up water supply.

5.2 GASIFIER (REFRACTORIES, BURNER, ASH REMOVAL)

Refractories

Introduction

Typically, the reactors, transfer lines, and cyclones of coal gasification systems are lined
with refractories to withstand the high temperature erosion/corrosion and slagging
conditions present. Under these conditions the refractory linings are subject to wear,
degradation, and ultimate failure, especially under the more severe slagging and
erosion/corrosion conditions. As this occurs, the performance and operating efficiencies
of the systems may decrease, while maintenance requirements increase. This can result
in increased production and maintenance costs. Therefore it is desirable to have
long-lived low-wear refractory linings for these applications.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 9
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Consequently, the Electric Power Research Institute, Inc. (EPRI) has sponsored several
research and development programs on refractories for coal gasification systems. The
results of this work, which constitutes much of the available state of the art information
and knowledge on refractories and refractory systems for coal gasification systems, is
published in four EPRI reports, listed as References 1, 2, 3 and 4.

Many of the refractories and refractory installations that have been used or tried in
slagging sections of slagging gasifiers are similar to, or are developments of, refractory
installations commonly used in the steelmaking industry. Reference 5 provides a
comprehensive overview of these types of refractory installations.

References 6 and 7 provide a more general background on the refractories and

refractory installations that have typically been used in the chemical process and
petroleum refining industries. Much of this information is also relevant to the design of
refractory installations for coal gasification processes.

The following paragraphs, derived from the Introduction and Summary of EPRI Report
AP-1268, Refractories for Coal Gasification and Combustion Systems, Reference 2,
provides a good overview of the process conditions and refractory selection and design
considerations for the slagging sections of gasifier reactors, gas transfer lines and
cyclones:

Process Conditions and Refractory Requirements

The process conditions found in coal gasification and combustion systems of interest to
the design and performance of refractory linings include:

Temperatures: Up to 2,000 oC (3,632 oF) in slagging systems

Up to 1,100 oC (2,012 oF) in nonslagging systems

Pressures: Up to 10 MPa (1,450 psi)

Gases: CO, CO2, CH4, H2, H2S, SO2, O2, N2 . . .

Gas Velocities: 1-3 m/s or 3-10 ft/s in fixed bed slagging units

10-30 m/s or 33-100 ft/s in gas transfer lines and cyclones

6-12 m/s or 20-40 ft/s in entrained bed slagging gasifiers along

walls

Solids: Coal, char, lignite, ash, dolomite, petroleum coke

Liquids: Slags, iron, salts or condensed phases

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 10
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

The refractory linings in the transfer lines, and cyclones are exposed to erosive solids
and gases which may cause the linings to wear by high temperature erosion/corrosion
mechanisms. The refractory linings in the slagging gasifiers and combustors are
exposed to molten slags which may cause wear by high temperature slag attack. The
gases which may attack the refractories includes CO, H2, and H2O, while the oxygen
partial pressure in the gas atmosphere of the slagging components may affect the slag
properties and in turn cause wear of the linings. Note that the transfer lines are located
between the gasifier and the syngas cooler (radiant cooler) or in between gasifier and
cyclone unit. Refer to Figure 2-14, 2-15 and 2-16 for the refractory locations for the
Texaco, Shell and Dow gasifiers respectively.

Carbon monoxide may cause refractories to literally crumble by CO disintegration

mechanisms in the presence of free iron, iron oxides, or iron phases in the refractories.
Dry H2 or water vapor may attack and weaken silica-containing refractories by
reduction-vaporization mechanisms as in the case of dry hydrogen or by steam
distillation in the case of water vapor. To avoid destruction or weakening of the
refractories in the presence of CO, H2 or H2O, low-iron, low-silica refractories are
required. However, the silica restriction may be relaxed for temperatures below 800 oC
(1,472 oF), while at higher use temperatures, the silica restriction may not be critical,
especially for dense refractories containing low-silica in the grain boundaries of fired
shapes or cement bonding phases of castable refractories, or if the silica exists as mullite
or other silicates.

The local oxygen partial pressure in contact with the slag affects the oxidation state of
the iron in the slag and, in turn, affects the melting temperature of the slag and the
reactions between the slag and the refractories. Under highly reducing conditions where
the iron exists in the elemental state, the reactivity of the slag toward refractories is
dependent primarily on the iron-free composition of the slag. However, in the case of
silicon carbide refractories, the elemental iron can react with the silicon carbide to form
low-melting ferrosilicons leading to refractory failure. Under oxidizing conditions the iron
in the slag is primarily in the ferrous state, which can have a significant effect on the
slagging of the refractories.

For the erosion/corrosion conditions found in the gas transfer lines, and cyclones, dense
high-strength refractories with low iron are required. At temperatures above 800 oC
(1,472 oF), the refractories should also have low silica, especially in the grain boundaries
of fired shapes or cement bonding phases of castable refractories. For the slagging
conditions found in the slagging gasifiers and combustors, the refractories should have
low solubility in the slag, high thermal conductivity, and high density. Low solubility is
extremely important in uncooled linings, while in linings where substantial water cooling is
used, high thermal conductivity may be more important.

Refractory Linings for Gas Transfer Lines and Cyclones

The refractory linings in gas transfer lines and cyclones are exposed to high velocity,
dilute phase erosion/corrosion conditions at temperatures below 1,100 oC (2,012 oF).
These conditions are most severe in the cyclones and in the transfer lines where
turbulence and changes in flow direction of particulate laden gas streams are found. The
linings in the gas transfer lines and cyclones also consist of dense working linings and
porous back-up insulating linings. The back-up insulating linings are mostly low-iron

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 11
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

(40-60 %) alumina castables. The dense working linings used in the pilot and small-scale
demonstration plants include several types of castables and fired shapes. High-purity
(94-96 %) alumina castables consisting of alumina aggregates and high-purity low-iron
low-silica calcium aluminate cements were installed in the original linings of many of
these plants. However, as excessive wear and failure occurred in the cyclones and gas
transfer lines in some plants, other refractories have been or may be tried. These
include: phosphate-bonded 90 % alumina plastics, fired shapes of silicon carbide with
oxide or self bonding, fired shapes of 90 % alumina with mullite bonding, and burned
phosphate-bonded 85 % alumina shapes.

EPRI has sponsored a study specifically addressing the design of refractories for
resistance to high temperature erosion-conditions. The results of this work are
documented in EPRI Report AP-1955, Reference 3. This report includes
recommendations for refractory installation in various pneumatic flow systems, guidelines
for the formation of refractory linings and recommendations for design geometry.

Refractory Linings for Slagging Gasifiers and Combustors

The refractory linings exposed to high temperature molten coal ash slags in slagging
gasifiers and combustors can experience severe wear and failure by slagging. There are
two types of lining designs now used for the slagging conditions: (1) thick refractory
linings consisting of fired or fused refractory shapes with or without water cooling as in
blast furnace practice, and (2) thin refractory linings consisting of refractory grains on
water-cooled walls as in commercial slagging boiler practice. Unlined metal walls with
substantial water cooling to freeze thin slag layers on the walls to act as the refractory
have been used in the past and are occasionally used now in a commercial
Koppers-Totzek slagging gasifier. The thin refractory lining design is preferred over the
unlined design as the thin refractory lining can provide protection for the metal wall during
initial heat-up prior to building up a protective continuous frozen layer on the walls and
during process upsets when temperatures may climb and remelt and destroy the frozen
slag layer leaving the metal wall unprotected.

Silicon-carbide and chrome-alumina refractories are mostly used in the slagging linings.
Fired shapes of nitride-bonded or oxide-bonded silicon carbide or solid solution bonded
chrome-alumina refractories are installed in many of the lining designs. Silicon carbide is
used in these designs because of its high thermal conductivity. Where the heat losses
are excessive or where oxidation of the silicon carbide is of concern, chrome-alumina
refractories are used. Fused alumina refractories which offer high slagging resistance
due to their high densities and low-to-moderate solubility in coal ash slags have been
investigated for use in those linings. However, spalling of the fused refractories is known
to occur during heat-up or during use.

EPRI Report AP-4589, Corrosion of Refractories in a Synthetic Coal Slag, Reference 4,

includes dynamic slag tests for several types of refractory, including fused-cast and
sintered products. The test results show that refractories containing more than 70 %
chrome have excellent resistance to corrosion by coal slags such as those found in many
advanced gasifiers.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 12
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Thick refractory linings initially wear at moderate to high rates until an equilibrium
thickness is left where thermal losses through the remaining refractory lowers the
slag-refractory interface temperature and reduces the slagging rate or provides a frozen
protective slag layer on the refractory.

In the thin refractory lining designs, silicon carbide refractory grains with chemical
bonding agents or cements are sprayed or gunned over water-cooled studded metal
walls. Silicon carbide is frequently used in this design, while other refractories having
lower thermal conductivity are also used. These include chrome-alumina, alumina or
other refractories. High-purity 94-96 % alumina monolithic refractories used for the
erosion/corrosion conditions in the other components of gasification systems have been
used for slagging in one of the pilot plants. Results on its performance are not available.
In commercial Koppers-Totzek slagging gasifiers, chrome-alumina refractory layers on
the water walls are used in preference to silicon carbide because of their lower thermal
conductivity. Silicon carbide is used, however, in many, if not most, of the commercial
slagging boilers which have been in operation for years. Lifetimes of several years are
experienced in these boilers though frequent repairs are made.

Major Areas of Concern

The major areas of concern for refractory linings in slagging and nonslagging gasification
and combustion systems where serious wear, degradation, and failure of linings may
occur, are:

Slagging sections of slagging gasifiers and combustors where the refractory

linings are exposed to highly corrosive coal ash slags found flowing along walls
and in static baths. Severe wear and failures of these linings have been
observed.

Highly erosive regions of cyclones and gas transfer lines where turbulence and
changing flow directions of high velocity particulate-laden gas streams are found.
Moderate to severe wear has been observed in the cyclones and gas transfer
lines.

In addition, failure by thermal shock under rapid temperature changes has caused some
problems in a number of components. Installation of uniform and reproducible refractory
linings is a recognized problem, especially in using castables and plastics whose final
properties can be greatly influenced by the installation technique and operator skill.
Other areas of concern for refractories are high temperature valves; solids transfer lines;
slurry pumps, valves, and lines; and heat transfer and gas quenching components.
Refractories or refractory linings may be used in these areas.

Much of the information and experience with refractories in coal gasification systems is
based on relatively short operating times, often in pilot plants or systems undergoing
process development. With longer operating times or larger scale commercial plants
other refractories problems or limitations may be identified that significantly impact
performance and life.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 13
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Burners

Burner design is dependent on the overall gasifier design. Each gasification process
utilizes a unique gasifier design.

There are three primary types of gasifier designs:

A descending bed of solids with upflowing gas

A fluidized bed of solids
Entrained solids

The entrained flow gasifiers, which are used in the Texaco, Shell and Dow gasification
processes, are the only types which employ what is generally defined as a burner, that is,
a device which mixes fuel and an oxidant in the correct quantities and with the proper
velocities to establish and maintain ignition of the mixture.

The burners used on entrained flow gasifiers are not independently designed and
engineered components. As noted above, burner design must be integrated with the
gasifier design. Factors affecting burner design are:

Type of fuel: dry solid, slurry, liquid, or gas

Type of oxidant: air or oxygen
Reaction temperature
Operating pressure
Capacity (rate of flow)

Regardless of the gasifier type and the type of fuel used, the burner employs simple
injectors which are designed to permit free and uninterrupted flows. The fuel mixing and
delivery system preceding the burner is critical to the proper operation of the gasifier.
The fuel feeding system generally is where most of the operational problems with the
various gasifier designs originate. An excessive oxygen to carbon ratio leads to
excessively high operating temperature, shortening refractory life. An insufficient ratio
leads to reduced carbon conversion or, in the extreme, coking within the gasifier.

Entrained flow gasifiers typically are categorized as one or two stage systems. In single
stage systems (both Shell and Texaco processes use this type) all of the gasification
takes place in a single chamber. These gasifiers are slagging type devices which have
an operating temperature above the ash fusion temperature of the slag. Oxygen is
typically the oxidant with such gasifiers. At the high temperatures attained in these
gasifiers the burner must either be cooled by water or utilize special refractories to
protect the burner components. Internal elements may be employed to shape and direct
the flame. (Note: This type of gasifier has a true flame envelope.) Again, material
selection must address the high temperature and erosive nature of the combustion
gases.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 14
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

The fuel and oxidant may be mixed directly at the point of injection into the gasifier or
separate injection points for fuel and oxidant may be used. For a given gasification
process the type of fuel and the type of oxidant (air or oxygen) will direct the burner
design. Variables in burner design include:

Number of injectors
Orientation (angle) of injectors
Staging of injectors (applicable to systems using separate fuel and oxidant
injectors)
Startup provisions

By varying the size, number and orientation of fuel and oxidant injectors, mixing and
turbulence in the combustion zone are controlled. With a fixed gasifier design, proper
residence time and temperature can be attained with a variety of feeds by burner
modifications alone. Generally, such modifications result from experimental testing and
trial burns.

Ash Removal

Molten slag flows freely down the gasifier water wall into a water-filled compartment
where it solidifies into dense, glassy granules when it comes in contact with the water
bath. The slag granules fall into a collecting vessel beneath the slag bath. The slag is
transferred to lock hoppers by gravity and washed with clean water to remove entrained
gas and any surface impurities during filling. After filling, a lock hopper is depressurized
and the slag dropped into a dewatering tank having an inclined, hard-faced mechanical
device such as drag conveyor to transfer the slag off the bottom and deposit the slag
granules on a belt conveyor for delivery to offsite storage and disposal.

5.3 WASTE HEAT RECOVERY

Synthesis gas plants have an abundance of waste heat available at various processing
steps. Figure 5-4, for example, depicts a typical composite heating/cooling curve for a
1,000 tpd Ammonia plant. It indicates the various locations of the heat sources and
summarizes the heat requirements for the steam system. In general, waste heat is
always present at the following locations:

(1) The raw synthesis gas exiting Reformers, Partial Oxidation reactors and
Gasifiers contain large amounts of high level sensible and latent heat.

(2) Another substantial source of high level sensible heat is usually present in the
flue gases exiting the radiant section of direct fired equipment and the gas
turbine exhaust.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 15
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Figure 5-4

HEAT SOURCES AND HEAT REQUIREMENTS FOR STEAM SYSTEM

OF AN AMMONIA PLANT 1,000 T.P.D.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 16
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

A large portion of waste heat is typically recovered by generating and superheating

steam, by preheating boiler feed water and condensate, and by preheating process
streams. Excess low level heat leaves the system via hot flue gas vents, cooling water
or cooling air, and equipment heat losses. In many cases, the plant is made
self-contained with regards to mechanical and electric energy by providing an auxiliary
boiler which provides additional steam to drive steam turbines. Alternatively gas turbines
may be utilized by feeding synthesis gas or natural gas to the gas turbine(s) for electric
power generation or for driving a compressor.

The heat recovery equipment on the process side consists usually of standard TEMA
type of exchangers with design temperatures not to exceed about 1,100 oF. Special
steam generation equipment is commonly used at higher temperature locations such as
the Reformer, Partial Oxidation reactor and Gasifier exits where the exposed metal, if not
cooled, requires protection by refractory. Other complications in the design of such
special equipment are:

The reformed gas must be cooled quickly in order to "freeze" its composition at
its high temperature equilibrium value.

Excessive thermal expansion of the various components.

Scaling.

Carburization (Metal dusting) and H2 attack (based on the Nelson curve data).

Additional fouling, erosion, and corrosion in case of partial oxidation of heavy oils
and coal gasification.

The equipment used for heat recovery from flue gas streams generated by direct fired
equipment is quite different from the equipment used on the process side since the
pressure of such gases is close to atmospheric. Ducts are used to guide the flue gases
in cross-flow over the various tube bundles to minimize pressure drop. The general
name for such a unit is Convection Section or Heat Recovery Steam Generation (HRSG)
unit. These units are normally very bulky and are easily recognized in the field
downstream of direct fired furnaces or gas turbines. An induced Draft (ID) Fan is often
associated with the convection section of the Reformer to draw the flue gases to the
atmosphere. The gas turbine back pressure is increased to allow the exhaust gas to flow
across the HRSG heat recovery coils, before venting to atmosphere.

5.3.1 Process Gas Boilers

There is a variety of Process Gas Boilers with more or less prolonged successful
operating records. In general they can be categorized as the fire-tube and
water-tube types. Both types may use water circulation based on "natural
circulation" (driven by gravity) or "forced circulation (driven by a pump). Less
utilized is the "once-through" system. A summary of the various types of Waste
Heat Boilers including their salient features can be found in Process Manual
Volume 27 "Hydrogen Plant Design," section 6.0.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 17
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

5.3.2 Convection Section or HRSG

These units form in general an integral system with an upstream direct fired
(Reformer) furnace or Gas Turbine. Section 5.1 of this manual provides a brief
description. Depending on the local permitting requirements, a bulky and costly
Selective Catalytic Reduction (SCR) unit may be required to lower NOx
emissions.

5.4 PARTICULAR REMOVAL/SCRUBBING

The syngas from a gasifier contains entrained unconverted carbon and ash particles.
These need to be removed prior to further syngas processing. The removal can either
be achieved using wet scrubbing or dry, barrier filters. The dry system normally utilizes
ceramic candle filters and will be demonstrated in many of the clean coal technology
projects.

System Description

In the case of wet scrubbing the particulate-bearing raw gas enters the scrubbing unit,
where contact with recycled process condensate and makeup water results in virtually
complete removal of solids from the syngas.

The partially-cooled particulate-bearing raw gas stream enters a wet scrubber

horizontally near its bottom vertical section, initially passing through a water spray to cool
the gas stream and remove the larger particulates. The gas stream continues upward
and passes through the one to three flooded baffle plates (stages). The clean gas
stream exits the top of the scrubber either vertically or horizontally. Dependent on
contamination level, all scrubbing water can be recirculated.

Wet Scrubber

Particulate removal is accomplished with a 2 to 3 stage wet scrubber. The scrubber

should be made of stainless steel. Water requirements are approximately
3 gpm/1,000 CFM of gas per stage. However, recirculated water slurries may be used
provided the ash concentration does not exceed approximately 5 % by weight, thus
reducing actual water requirements to 1.25 - 1.75 gpm/1000 CFM per stage. Also
depending on the degree of cooling, the recirculated liquid may require a heat exchanger.
A complete scrubber packaged unit with recirculation system, pH control system (if
required) and instrumentation is available. (Figure 5-5). Typically, various gasification
licensors offer different versions of their proprietary scrubber designs as a part of the
gasification system know how.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 18
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Figure 5-5

TYPICAL WET SCRUBBER

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 19
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

The solids scrubbed from the gas exit via the scrubber and gasifier blowdown streams.
The solids concentration in these streams is typically limited to 1-5 wt% solids.

5.5 PROCESS CONDENSATE TREATMENT

The process condensate treatment system varies among various gasification processes.
In general, the process condensate treating system processes aqueous streams from the
raw gas scrubbing and ash cooling operations to remove dissolved gas components and
suspended solids prior to recirculation of this water. Additionally, this system treats the
net process effluent to remove dissolved solids and biodegradable compounds. There
may be pretreatment steps to remove materials damaging to a bio pond before this water
is used as makeup to the cooling water and ash handling systems or for disposal. Refer
to the Texaco waste water treating process.

System Description

The Shell gasification process condensate treatment system is described to illustrate the
various process steps.

Sour Water Stripping

Process water purged from the Wet particulate Removal System and condensate from
the Tail Gas Treating System are fed to the sour water stripper for removal of ammonia
and hydrogen sulfide. A feed drum is provided with adequate holdup volume to avoid
stripper column upsets that could occur due to variations in the feed rate and feed
composition.

Intermediate pressure steam provides the necessary heat and stripping medium in the
column to reduce the ammonia level in the water to less than 50 ppm by weight
concurrently removing essentially all the hydrogen sulfide and dissolved raw gases. The
acid gas containing ammonia from the Sour Water Stripper (SWS) overhead accumulator
is sent to the Sulfur Recovery Unit. The stripper bottoms, which still contains a minor
amount of suspended solids, is cooled by cooling water and fed to the Effluent Water
Treating Unit.

Effluent Water Treating

The effluent water treating process consists of process water clarification and solids
concentration of suspended flyslag, slag and biosludge followed by biotreatment for
biological oxygen demand (BOD) reduction and nitrification.

The sour water stripper bottoms, which contain a minor amount of suspended solids, is
fed to the process water clarifier. The clarifier provides sufficient residence time, with the
aid of a flocculent for the bulk of the suspended solids to settle. Solids in the clarifier
underflow are further concentrated and dewatered by filtration and then mixed with
biosludge from the biotreatment phase and diluted with treated water. The slurry is sent
to the pug mill in the Flyslag Handling and Storage System. The process water clarifier
overflow is pumped to an equalization/surge tank where it is mixed with contaminated

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 20
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

storm water runoff collected from about three acres of concrete pads in the process
areas.

From the equalization tank, the combined effluent is then subjected to further clarification
in a primary clarifier. The small quantity of underflow from the primary clarifier is recycled
to the process water clarifier. The overflow is sent to a series of rotating biological
contactors to ensure nitrification of the residual ammonia and any other nitrogen
compounds present in the overflow stream. A small amount of nutrient phosphorous is
added to the clarifier overflow, as well as sodium bicarbonate/sodium hydroxide to control
alkalinity.

The effluent from the biotreaters contains a small amount of suspended biosludge. The
biosludge is separated in a "Lamella"-type secondary clarifier and mixed with
concentrated solids from process water clarification as described above. A portion of the
treated water from the secondary clarifier is used for slag handling system makeup and
for flyslag wetting. The remainder is pumped to disposal.

5.6 OXYGEN PLANTS

The overall air separation process includes the following steps:

Air Compression
Air Purification
Cooling of air to liquefaction temperature
Separation into components by low temperature fractionation
Reheating of separated components
Pumping and/or Compressing of products to the desired pressures.

Atmospheric air contains significant variable quantities of dust, water, carbon dioxide,
and hydrocarbons. These impurities must be removed to ensure optimum plant
performance. Three purification methods can be employed.

Reversing Heat Exchangers

Regenerators
Molecular Sieves

The purified air is a gaseous mixture of oxygen, nitrogen, argon and certain rare gases in
fixed quantities. These components are separated through the use of low temperature
fractionation. The refrigeration process used to reach liquid air temperature is
regenerative. Warm process air entering the plant is cooled by the separated products
before leaving the plant. The additional refrigeration duty required is generated through
expansion of air and/or nitrogen (Joule - Thompson).

A number of different cryogenic processes are available to recover oxygen from air.
These processes can be categorized as follows:

Low Pressure Double Column Process

Medium Pressure Double Column Process
High Pressure Double Column Process
Single Column Process

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 21
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

It is not possible to state that one particular process cycle is superior. The process
selection is influenced by:

Plant Capacity
Number of products - coproduction of nitrogen and argon
Final pressure required for product(s)
Purity of product(s)
Gas and/or liquid oxygen production requirements
Power and utilities cost
Investment cost
Plant turndown requirements

Major suppliers of turnkey oxygen plants are:

Liquid Air
Lotepro (Linde AG)
Praxair
Air Products
Airco (British Oxygen Corporation)

There are three alternative methods of producing high pressure oxygen:

All centrifugal compression

Centrifugal compression plus booster reciprocating compression
Liquid pumping and vaporizing at high pressure

Each scenario appears to have its particular advantages and disadvantages. Therefore,
the most suitable configuration has to be determined on a case to case basis. A
selection is normally made based on a trade-off between investment, power
consumption, experience, and safety.

Some manufacturers of centrifugal oxygen compressors are Clark, Demag, and Sulzer.
Reciprocating oxygen compressors may be supplied by Linde (Lotema), Sulzer, and
Worthington. Lotepro is the only liquid oxygen pump supplier known as of the date of
this writeup (December 1993).

The oxygen plant is the largest mechanical power consumer in the synthesis gas plant
and heat integration is therefore of prime importance. It is usual to study in detail the
option of steam versus electric drive and analyze the consequences on the overall layout
of the synthesis gas plant steam system. The use of gas turbines as the mechanical
driver can also be considered if this scheme would fit in the overall synthesis gas plant
heat recovery system.

The concept of an Integrated High Pressure Oxygen Plant for reducing the heat rate of
Integrated Gasification Combined Cycle (IGCC) power plants has been recently
developed. A slipstream of the compressed air can be extracted from the gas turbine to
supply the air feed for the oxygen plant. The cold box in the "high pressure" oxygen
plant will operate at 5-6 bar such that the separated oxygen and nitrogen streams are at
the pressure. Also, the concept aims to use the nitrogen stream from the oxygen plant
as the

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 22
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

soot-blowing gas and for injection into gas turbine after further compression. Following is
a brief review of two different studies conducted by Fluor Daniel.

(1) Integrated high pressure versus non-integrated low pressure air separation cases
were evaluated for IGHAT plants based on an FT4000 turbine. A separate air
compressor was required for the integrated case since the available air pressure
was lower than the required pressure for the Oxygen Plant. Also, the integrated
configuration was not able to return nitrogen to the compression cycle because
of potential combustor problems. Therefore, a nitrogen expander was added to
the heat recovery scheme. The overall result shows a potential 2 % gain in heat
rate of the integrated case versus the non-integrated case. However, at the
particular time it was concluded that the technological and economic obstacles
outweighed the heat rate benefits.

(2) Similar to the IGHAT analysis another study was conducted for DESTEC IGCC
using GE 7FA Gas Turbines. In the integrated scheme for this study, air is
directly delivered to the oxygen plant. The nitrogen from the oxygen plant first
cools the air to the oxygen plant before returning to the compression/expansion
cycle. A potential 2.6 % gain in heat rate can be achieved at the expense of a
very slightly increased $/kW total plant cost of 0.16 %.

Gas Turbine World magazine (January-February 1993) reports that the Dutch Demkolec
(Demo KV-STEG) design uses an oxygen blown entrained-bed 2,000 MTPD Shell
gasifier and incorporates an advanced 1,700 TPD air separation unit (ASU) developed by
Air Products & Chemicals. Demkolec requires a fully integrated air plant (ASU air
extracted from and residual nitrogen returned to the Siemens/KWU 156-MW Model
V94.2 Gas Turbine).

The overall plant efficiency (coal to net electricity) is projected to be 43 % (LHV basis) for
a heat rate of approximately 7,950 Btu/kWhr.

5.7 SOLID FEED SYSTEMS

The solid feed system is very specific to any gasification technology. The Texaco and
Dow technologies are slurry-based and the Shell technology is dry, ground solid-based.
The following description pertains to the Shell system and is included to illustrate the
various steps of a typical solid feed system.

Coal Receiving and Handling

Coal is unloaded from the train at the coal receiving station. The coal receiving station is
situated at an elevated section of track 26 ft above grade. All coal handling equipment is
located at or above grade because of the high water table of the surrounding site. Coal
is unloaded from 100-ton bottom dump cars into unloading hoppers. Coal is withdrawn
from each hopper by a vibrating feeder and placed on receiving conveyors (one per
hopper) which transport the coal to the unloading conveyor. The single boom stacker
receives coal from the unloading conveyor.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 23
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

Space for a reserve pile is provided adjacent to the coal receiving station. The dead pile
is sodded to minimize dust and coal fines entrainment in rainfall runoff.

Coal is reclaimed from the storage piles by a bridge-type bucket wheel reclaimer. The
wheel moves across the face of the pile, making an angle of repose cut across the many
layers of coal, thereby blending the coal fed to the gasification plant. This blending
provides more uniform gasifier operation. Coal is then transferred to the coal drying and
grinding system via a series of process conveyors and transfer towers.

Mobile equipment reclaims and transports coal from the dead coal pile to the dead coal
load-out hopper. Coal from the hopper is conveyed to a process conveyor transfer
tower.

The coal receiving station is enclosed. A baghouse is used to minimize dust

concentration in the receiving station during rail car unloading. All other coal handling
systems are equipped with a dust suppression system consisting of water spray aided by
a wetting agent.

Coal Drying and Pulverization

The coal drying and pulverization unit is composed of multiple parallel roller mills. Coal is
ground to a specification of 90 wt% less than 88 microns and 5 wt% less than 5 microns,
and dried to 5 wt% in a one step process. A steam heated gas stream provides the
drying energy requirements and carries the evaporated water from the system as it
sweeps the sized product coal through an internal classifier for collection in a baghouse.
By-product nitrogen from the air separation unit is used for makeup. Mill gases are
partially recycled to reduce heating requirements.

Delivery of dried/ground coal to the gasifier feeding system is accomplished using a

pneumatic conveying system.

Milled Coal Pressurization and Feeding

Milled and dried coal is pneumatically transported from storage in the coal preparation
area to the coal feed system for pressurization and transport to the gasifier. Each of the
three gasifier coal feed systems consists of a receiving vessel, two lock hoppers and a
feed hopper.

The incoming ground coal is separated from its transport medium(N2) in the receiving
vessel. The separated coal collects in the bottom of the receiving vessel and is
periodically transferred to one of the two accompanying lock hoppers. The two lock
hoppers are operated on a time cycle (programmable logic controlled) such that one is
filled and pressurized while the other is emptied and depressurized. Once a lock hopper
had been charged with coal from the receiving vessel, the lock hopper is then
pressurized with high-pressure nitrogen and its contents are subsequently discharged
into the feed hopper. After emptying, the lock hopper is depressurized and readied for
the next batch of coal from the receiving vessel. Pressurized coal is continuously
withdrawn from the feed hopper and pneumatically conveyed with nitrogen to the
gasifier's coal burners.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 24
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

The nitrogen which is separated from the incoming coal in the receiving vessel is
recycled to the milling and drying system through bag filters located in the receiving
vessel. Nitrogen vented from the empty lock hopper during the depressurization step is
filtered and discharged to the atmosphere.

5.8 SHIFT REACTORS

General

The H2/CO ratio of the synthesis gas produced with Tubular/Auto Thermal Reforming,
Partial Oxidation or Gasification varies somewhere between 0.5 and 1.0. Shift Reactors
are used to adjust this ratio and obtain the right stoichiometric composition for the
conversion of synthesis gas to hydrogen, methanol, ammonia, SNG, oxo-alcohols, or
Fischer Tropsch products. A single shift reactor may be sufficient for minor ratio
adjustments, or a number of shift reactors in series may be required for major
adjustments or for maximum CO conversion.

The water gas shift reaction is moderately exothermic and equilibrium is favored by low
temperatures. For most practical applications the reaction is independent of the
operating pressure.

The operation of a shift reactor is based on a compromise between CO conversion and

activity. Shift catalyst is designed for end-of-run (EOR) conditions and is operated at
reduced temperature at start-of-run (SOR) conditions. As the shift catalyst ages, the
inlet temperature is gradually increased to restore activity at the expense of CO
conversion. Good control is paramount since excessive temperatures cause premature
irreversible catalyst aging.

Catalyst vendors such as Katalco, United Catalyst, BASF, or Haldor Topsoe provide
different catalyst formulations for operations at different temperature levels.

High Temperature Shift (HTS) catalyst operates at about 625-990 oF and

consists typically of iron oxide/chromium oxide tablets with a bulk density of
about 70 lb/ft3. An alternative HTS catalyst offered by Haldor Topsoe is Copper
based and operates at about 480-840 oF.

Medium Temperature Shift (MTS) catalyst offered by Haldor Topsoe operates at

about 390-660 oF and consists of copper oxide/zinc oxide/alumina. This catalyst
has not enjoyed much popularity.

Low temperature Shift (LTS) catalyst operates at about 340-530 oF and consists
of Copper Oxide/Zinc Oxide/Alumina pellets with a typical bulk density of about
55 lb/ft3.

The raw synthesis gas from tubular/autothermal reformers is usually clean. However, the
raw synthesis gas from partial oxidation or gasification may contain impurities such as
H2S, COS, NH3, HCN and formates. The "sweet" or "clean" shift catalyst does not
perform well under such conditions. A special "dirty" or "sour" shift catalyst has been
developed for such applications by BASF, United Catalyst and Haldor Topsoe. A
minimum sulfur content is necessary to keep the active metals in a sulfided (active) state.
Sour shift catalyst operates best at a temperature range between 390-950 oF provided

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 25
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

that the feed gas temperature is at least 36-45 oF above the gas dewpoint. The catalyst
typically consists of Cobalt/Molybdenum oxide (on a special carrier) extrudates with a
bulk density of about 46 lb/ft3.

HTS Catalyst

Normal HTS catalyst requires initial reduction of the iron oxide (Fe2O3) to magnetite
(Fe3O4). HTS catalyst is very robust and is resistant to the weakening effects of liquid
water and alkali. Its activity can, however, be affected by concentrations of halogens.
Sulfur is not a poison in the normal sense. At high inlet sulfur concentrations the catalyst
is converted to a sulfide form which has approximately half of the activity of unsulfided
catalyst. As supplied, the catalyst has a low sulfur content to minimize the period of
desulfurization during start-up. Normal wet gas space velocities are in the range of
1,000-5,000 volumes of gas at STP per hour per volume of catalyst.

Highly active HTS catalyst offered by Haldor Topsoe minimizes the potential of
by-product hydrocarbon formation at lower steam to dry gas ratio. Methanol formation
will be at the equilibrium value. The amount, however, is insignificant because of
thermodynamic limitations. The catalyst requires initial reduction of the copper oxide to
copper and may need a dedicated start-up heater. The operating principles are similar to
those for normal HTS catalyst. However, this catalyst is more sensitive to moisture,
sulfur/halogen poisons and overheating. Therefore, more stringent operating procedures
have to be followed to prevent premature deactivation.

MTS and LTS Catalyst

Both MTS and LTS catalyst require initial reduction of the copper oxide to copper and
may need a dedicated start-up heater. The operating principles are similar to those for
normal HTS catalyst. However, these catalysts are more sensitive to moisture,
sulfur/halogen poisons and overheating. Therefore, more stringent procedures have to
be followed to prevent premature deactivation. Normal wet gas space velocities are in
the range of 2,000-5,000 volumes of gas at STP per hour per volume of catalyst. A 30 oF
minimum temperature approach to dewpoint of the feed gas should be assumed to
prevent water condensation. Note that sufficient amount of methanol is formed to
present problems in the process condensate.

Sour Shift Catalyst

Sour Shift catalyst requires presulfiding prior to operation to reach full activity. A
dedicated start-up heater is recommended. This type of catalyst is to a great extent
unaffected by catalyst poisons as contained in low concentrations in process gas from
the partial oxidation of heavy fuel oil or gasification of coal. It is essential that the
catalyst is operated in a sulfurized condition. Therefore, use of this catalyst with gases of
low sulfur content should be avoided. Also, during shutdown the admission of oxygen
must be prevented as the catalyst is pyrophoric in the sulfided state and steam purging
should be carried out only briefly to prevent desulfurization and reoxidation.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 26
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

5.9 ACID GAS REMOVAL

A variety of processes are commercially available or under development for acid gas
removal. Most processes are proprietary and are known by trade names. This manual
provides information on some of the "Selective" processes for coal gasified synthesis
gases. These are as follows:

The Union Carbide Selexol process.

Shell Development Company Sulfinol process.

Linde A.G. Rectisol "selective"(a) process and Lurgi Standard Rectisol

(nonselective) process.

MDEA based solvents such as Dow Chemicals' GAS SPEC and Union Carbide's
UCARSOL solvents.

Selective processes are not so critical with hydrocarbon gasifiers associated with power
plants because of the low content of CO2 in the sour syngas.

The Selexol process uses physical solvent which is a dimethylether of polyethylene

glycol. This preferentially removes the H2S over CO2, but the relative concentrations of
these two compounds in the feed gas can greatly impact the absolute quantity of gas
species removed.

The Sulfinol process uses physical and chemical solvent. The physical absorption
constituent of the solvent (sulfolane) adds physical solubility of the acid gases which is
proportional to the partial pressure of the acid gases. The chemical absorption
constituent is diisopropanolamine (DIPA) Sulfinol-D; or methyl diethanolamine (MDEA)
Sulfinol-M. Sulfinol-D is generally used in applications where the H2S concentration is
relatively low.

The Rectisol process uses refrigerated methanol and is licensed by both Linde AG and
Lurgi Kohle und Mineralöltechnic GmbH. Traditionally, Linde has designed all selective
Rectisol units and Lurgi has designed all nonselective (bulk) or "standard" Rectisol units.
Linde offers the Rectisol II process utilizing cold toluene/methanol mixture as the solvent.

Major equipment used for the acid gas removal system are as follows:

Absorber
Flash Drum
Stripper
Stripper Reboiler
Lean/Rich Solvent Exchanger
Stripper Overhead Condenser
Regenerator Accumulator
Pumps (lean amine circulation, reflux and etc.)
Lean Solvent Cooler
Refrigeration Unit (for Rectisol and Selexol units only)
(a)
Selective process removes H2S without removing much CO2.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 27
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

The material of the majority equipment is carbon steel for both the Selexol process and
the Sulfinol process. However, the Rectisol process uses much stainless steel
equipment. The Rectisol process can be much more complex, particularly with regard to
removal of iron and nickel carbonyls.

Plate-type heat exchangers for the lean/rich solvent exchanger service are less costly
than conventional shell-and-tube exchangers.

Heat integration within the Rectisol unit is quite complex in order to reduce refrigeration
requirements. Low processing temperatures necessitate refrigeration (about - 40 oF)
which is usually supplied by either a propane, propylene or ammonia refrigeration unit.

For further details, refer to the pertinent Fluor Daniel process design manual as follows:

Selexol Process Design Guide

Selective Acid Gas Removal Processes
Process Volume 35 - Sour Water Stripper
MDEA Gas Treating Process Design Guide

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 5.0
SYNGAS GENERATION
PAGE 28
PROCESS MANUAL EQUIPMENT CONSIDERATIONS
DATE 08-94

5.10 REFERENCES

1. Copyright © 1979. Electric Power Research Institute. EPRI AF-1151. Design of

Refractories for Coal Gasification and Combustion Systems. Reprinted with
Permission.

2. Copyright © 1980. Electric Power Research Institute. EPRI Report AP-1268.

Refractories for Coal Gasification and Combustion Systems. Reprinted with
Permission.

3. Copyright © 1981. Electric Power Research Institute. EPRI Report AP-1955.

Design of Refractories for Resistance to High-Temperature Erosion-Corrosion.
Reprinted with Permission.

4. Copyright © 1986. Electric Power Research Institute. EPRI Report AP-4589.

Corrosion of Refractories in Synthetic Coal Slag. Reprinted with Permission.

5. The Making, Shaping and Treating of Steel, Ninth Edition, Chapter 2, edited by
H.E. McCannon, Published by United States Steel.

6. Refractories for the Chemical Process Industries, MTI Manual 9, by E. Ruh,

published by the MTI.

7. Process Industries Corrosion, Page 661 - Refractories, by M.S. Crowley,

published by NACE.

8. Copyright © 1983. Electric Power Research Institute. EPRI Report AP-3129.

Shell-Based Gasification-Combined-Cycle Power Plant Evaluations. Reprinted
with Permission.

K:\WRK090\037\345\MANUALS\SYNGAS\009-05.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 1 of 15
PROCESS MANUAL APPENDIX
DATE 08-94

1.0
2.0
3.0
4.0
5.0

6.0 APPENDIX

6.1 LIST OF MAJOR FLUOR DANIEL PROJECTS

Coal Gasification

WESCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1972
EPRI Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Various
Commonwealth Edison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1974
H-Coal (Liquefaction Residue Gasification) . . . . . . . . . . . . . . . . . . . . . . . . . . 1975
Sasol II & III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1975
Advanced Coal Liquefaction Including Char Gasification . . . . . . . . . . . . . . . 1977
Montebello Pilot Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1980
Hampshire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1983
Great Plains Gasification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1983
Tennessee Eastman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1983
Cleveland Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1984
Niagara Mohawk Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1986
Bonneville Power Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1986
PEPCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1986
Public Service of Indiana . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1986
FPL Site-Specific Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1986
Salt River Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1987
Southern California Edison Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1987
Shell Process Enhancement Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1987
Gas Research Institute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1988
Texaco Process Enhancement Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1988
Gilbert Repowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1989
Delaware Clean Energy Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990
Texaco Cool Water Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990
Teco Power Service Reconfiguration Study . . . . . . . . . . . . . . . . . . . . . . . . . 1991
Destec Illinois #6 Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1991
Tamco Power Partners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1991
Molten Metal Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1992
Bonneville Power Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1992
Wisconsin Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1992

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 2
PROCESS MANUAL APPENDIX
DATE 08-94

6.2 GASIFICATION EXPERIENCE BY TECHNOLOGY

Technology Feedstock Products Projects Studies

Texaco Coal: IL, PA, KY, MO, UT, WY, Hs, MeOH, NH3 Texaco Montebello, CA 42
OH, MD, TN, AR, Australian, SNG, Fuel Gas Texaco Convent, LA
Canadian, South African, Liquid Fuels ELF France
Chinese, German, Italian, Combined Cycle Confidential U.S. Client
Japanese Cogeneration Mississippi River Fuels
Lignites: TX, ND, Greece Oxo Chemicals Cool Water
Coal Liquefaction Residue Reducing Gas Delaware Clean Energy
Anthracite Carbon Monoxide Project
Sewage Sludge AGIP
Refinery Wastes Yabucoa Energy Project
Coke: Delayed, Fluid
Coal Liquids
Hydrocarbon Liquids

Lurgi Coal: IL, KY, NM, WY, South SNG, MeOH SASOL II & III 21
Africa, Brazil Fuel Gas Wesco
Lignite: ND, TX Liquid Fuels Commonwealth Edison
Combined Cycle Great Plains

BGL Coal: IL, OH, Australian SNG 4

Combined Cycle

KRW Coal: IL, PA, KY, WY, UT, Syngas SASOL Demo Unit 12
South Africa, Brazil Fuel Gas
Lignite: ND, TX Combined Cycle

Shell Coal: IL, OH, MD H2, SNG, Alcohols Texas Eastern 8

Lignite: TX, New Zealand Fuel Gas, MeOH Florida Power and Light
Hydrocarbon Liquids Combined Cycle Oxochem Enterprises
Natural Gas Niagara Mohawk
Bonneville Power
Administration

DESTEC Lignite: New Zealand, TX MeOH, Combined 5

Coal: WY, MD, PA, IL Cycle

H.T. Winkler Lignite: New Zealand MeOH 1

Tosco Coke: Fluid, Delayed H2, MeOH Rocky Flats Pilot Plant 6
Fuel Gas
Combined Cycle

Koppers/ Coal: IL, WY, Brazil SNG, MeOH 3

Totzek Lignite: TX Fuel Gas

KBW Coal: WY Liquid Fuels Hampshire 1

Kilngas Coal: IL, OH Combined Cycle 2

Wellman Coal: UT Combined Cycle 1

Total 14 106

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 3
PROCESS MANUAL APPENDIX
DATE 08-94

GASIFICATION EXPERIENCE SUMMARY SINCE 1981 (Continued)

Coal-
Combined Fired Process Plants
Coal Gasification Cycles Combustion Power (Process)
Project Plant (Process) (Vendor) Turbines (Vendor) Plants

Texaco, West Virginia/ Texaco G.E. G.E. Gas Cleanup(a)

New Jersey
ERC/METC Lurgi, BGL, Texaco, Yes Gas Cleanup(a)
Shell, KRW, Exxon Fuel Cells
Bonneville Power Shell, Dow G.E. G.E. Gas Cleanup(a)
Administration
Florida Power and Light Shell G.E. G.E. Gas Cleanup(a)
Company
Niagara Mohawk Shell G.E. G.E. Gas Cleanup(a)

Potomac Electric Texaco, Shell, DOW G.E., Vogt G.E. Gas Cleanup(a)
Power Company
Cleveland Electric BGC, Kilngas, Texaco, G.E. G.E. Gas Cleanup(a)
Illuminating Company Shell Fuels
Coproduction
Utah Power and Light Wellman-Galusha, KRW G.E. Yes Gas Cleanup(a)

Texaco, Montebello Texaco

Hawaiian Electric Texaco Yes Gas Cleanup(a)

Company
PPG KRW G.E. G.E. Gas Cleanup(a)
Westinghouse Westinghouse
Salt River Project Texaco GE GE Gas Cleanup

Southern California Texaco GE GE Gas Cleanup

Edison
Mobil Cogeneration Texaco G.E. Gas Cleanup(a)

TECO Power Services Lurgi, Texaco G.E. G.E. Gas Cleanup(a)

(Both
conventional
and hot gas
cleanup)
Gasification Texaco G.E. G.E. Gas Cleanup
Enhancement Study
Cool Water Texaco G.E. G.E. Gas Cleanup(a),
Ammonia,
Carbon Dioxide
AGIP Texaco GE GE

DCEP Texaco G.E.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 4
PROCESS MANUAL APPENDIX
DATE 08-94

GASIFICATION EXPERIENCE SUMMARY SINCE 1981 (Continued)

Coal-
Coal Gasification Combined Fired Process Plants
Plant Cycles Combustion Power (Process)
Project (Process) (Vendor) Turbines (Vendor) Plants

Gas Research Institute Texaco, KRW, Lurgi, Gas Cleanup(a)

BGC Fuels
Production
Great Plains Coal Lurgi Gas Cleanup(a)
Gasification Project
SASOL II and III Lurgi Yes Gas Cleanup(a)

EPRI, AP3129 Shell G.E. G.E. Gas Cleanup(a)

EPRI, RP2029-4 KRW G.E. G.E. Gas Cleanup(a)

EPRI, RP2029-10 Texaco G.E. G.E. Gas Cleanup(a)

EPRI, RP2029-13 Texaco G.E. G.E. Gas Cleanup(a)

EPRI, RP2029-15 Texaco G.E. G.E. Gas Cleanup(a)

EPRI, RP2162-1 Texaco G.E. G.E. Gas Cleanup(a)

EPRI, RP2477-1 Texaco G.E. G.E. Gas Cleanup(a)

EPRI, RP2773-10 Texaco G.E. G.E. Yes Gas Cleanup(a)

EPRI Dow G.E. Gas Cleanup(a)

Notes:
(a) Includes full scope of sulfur removal/recovery, gas cooling, gas conditioning; wastewater treating, and
offsite/utility systems as required.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 5
PROCESS MANUAL APPENDIX
DATE 08-94

6.3 UTILITIES CONSUMPTION AND PRODUCTION

The auxiliary power consumptions by the various plant sections in the three base case
designs at full capacity are summarized in Tables 6-1, 6-2 and 6-3. Power consumption
at three different ambient conditions and two supplemental firing modes is listed in each
table. For further details, refer to the EPRI report AP-3486, Volume 2, April 1984,
Reference 13 in Section 2.0.

6.4 COST ESTIMATE

6.4.1 Data Base

Fluor Daniel has developed an extensive cost data base for the various
process/utility units for the following gasification technologies:

a. Lurgi
b. Texaco
c. Westinghouse
d. Shell
e. Destec

In addition, the cost data base includes data on various technologies for acid gas
removal, ammonia recovery, sulfur recovery, shift conversion, gasification feed
preparation, gas cooling, reforming, methanol synthesis. Utility unit costs have
been developed as well.

Attachment "A" lists all the units that have been 'normalized' for capital cost
estimate. The estimating group at Advanced Technology Business Unit has
developed a list showing the reference capacities and the capital cost
components of the various process units. The user needs to specify the number
of trains and the capacity per train for the various process units. For a given
time frame and the plant location, the capacity factors will be utilized to estimate
the capital costs of the various units in the plant. For the more recent activities
(e.g., Destec Studies), the estimating group has developed additional cost data
that can be utilized for the required capacities by factoring using the reference
cases.

Also, the various EPRI references cited in this report contain description on the
capital and operating cost estimating methodologies for the various gasification
technologies. Components of the plant investment such as the direct field
material and labor costs, indirect field and home office engineering costs, sales
tax, initial catalysts and chemicals' cost, contingency are discussed. Also, the
total capital required consists of prepared royalties, spare parts inventory,
organization and start-up costs, working capital, allowance for funds during
construction and land in addition to the plant investment.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 6
PROCESS MANUAL APPENDIX
DATE 08-94

Table 6-1

POWER CONSUMPTION SUMMARY

RADIANT PLUS CONVECTIVE DESIGN(a)
(Design Basis: Texaco Gasifier/Illinois No. 6 Coal, Plant Location: Chicago, 95 % Sulfur Removal)

AMBIENT TEMPERATURE, oF/ NSF or SF(b) 20/NSF 59/NSF 88/NSF 59/SF 88/SF
Unit Name Power Consumption, kW
10 Coal Handling and Slurry Preparation 5,297 4,762 4,414 5,297 5,297
(c)
11 Oxidant Feed 72,971 68,744 66,892 76,466 80,269
20 Gasification and Ash Handling 914 822 762 914 914
21 & 25 Gas Cooling and Fuel Gas Saturator 1,921 1,729 1,601 1,906 1,901
22 Acid Gas Removal 4,161 3,741 3,468 4,161 4,161
23 Sulfur Recovery 239 215 200 239 239
24 Tail Gas Treating 695 625 579 695 695
30 Steam BFW, and Condensate System 404 377 359 431 449
(d)
32-45 General Facilities (excluding 40) 9,051 8,619 8,540 10,074 10,964
40 Process Condensate Treating 1,134 1,019 945 1,134 1,134
51 Steam System 194 179 170 200 207
TOTAL PLANT POWER CONSUMPTION, kW 96,981 90,832 87,930 101,517 106,230
Gross Power Produced, kW 754,648 679,796 623,970 737,210 716,279
Net Power Output, MW 657.67 588.96 536.04 635.69 610.05

Notes
(a) kW At Full Design Capacity
(b) NSF = No Supplemental Firing; SF = Supplemental Firing
(c) Power Consumed by the air and oxidant compressors less power recovered from the expander.
(d) 85 to 88 % of this power demand is attributable to the Cooling Water System pumps and fans.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 7
PROCESS MANUAL APPENDIX
DATE 08-94

Table 6-2

POWER CONSUMPTION SUMMARY

RADIANT ONLY DESIGN(a)
(Design Basis: Texaco Gasifier/Illinois No. 6 Coal, Plant Location: Chicago, 95 % Sulfur Removal)

AMBIENT TEMPERATURE, oF/ NSF or SF(b) 20/NSF 59/NSF 88/NSF 59/SF 88/SF
Unit Name Power Consumption, kW
10 Coal Handling and Slurry Preparation 5,652 5,083 4,708 5,652 5,652
(c)
11 Oxidant Feed 77,833 73,344 71,321 81,559 85,617
20 Gasification and Ash Handling 643 578 536 643 643
21 & 25 Gas Cooling and Fuel Gas Saturator 1,898 1,851 1,603 1,913 1,907
22 Acid Gas Removal 968 870 806 968 968
23 Sulfur Recovery 255 229 212 255 255
24 Tail Gas Treating 741 666 617 741 741
30 Steam BFW, and Condensate System 538 500 476 559 573
(d)
32-45 General Facilities (excluding 40) 9,083 8,689 8,608 10,206 11,053
40 Process Condensate Treating 1,210 1,088 1,008 1,210 1,210
51 Steam System 213 192 188 223 232
TOTAL PLANT POWER CONSUMPTION, kW 99,034 93,090 90,083 103,929 108,851
Gross Power Produced, kW 770,798 693,009 636,395 749,315 726,136
Net Power Output, MW 671.76 599.92 546.31 645.39 617.28

Notes:
(a) kW At Full Design Capacity
(b) NSF = No Supplemental Firing; SF = Supplemental Firing
(c) Power Consumed by the air and oxidant compressors less power recovered from the expander.
(d) 85 to 88 % of this power demand is attributable to the Cooling Water System pumps and fans.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 8
PROCESS MANUAL APPENDIX
DATE 08-94

Table 6-3

POWER CONSUMPTION SUMMARY

TOTAL QUENCH DESIGN(a)
(Design Basis: Texaco Gasifier/Illinois No. 6 Coal, Plant Location: Chicago, 95 % Sulfur Removal)

AMBIENT TEMPERATURE, oF/ NSF or SF(b) 20/NSF 59/NSF 88/NSF 59/SF 88/SF
Unit Name Power Consumption, kW
10 Coal Handling and Slurry Preparation 5,652 5,083 4,708 5,652 5,652
(c)
11 Oxidant Feed 77,833 73,344 71,321 81,559 85,617
20 Gasification and Ash Handling 596 536 496 596 596
21 & 25 Gas Cooling and Fuel Gas Saturator 1,463 1,350 1,328 1,523 1,543
22 Acid Gas Removal 968 870 806 968 968
23 Sulfur Recovery 255 229 212 255 255
24 Tail Gas Treating 741 666 617 741 741
30 Steam BFW, and Condensate System 530 501 477 561 575
(d)
32-45 General Facilities (excluding 40) 9,260 8,872 8,796 10,304 11,219
40 Process Condensate Treating 1,210 1,088 1,008 1,210 1,210
51 Steam System 198 184 174 214 224
TOTAL PLANT POWER CONSUMPTION, kW 98,706 92,723 89,943 103,583 108,600
Gross Power Produced, kW 739,446 663,414 606,315 716,046 693,838
Net Power Output, MW 640.74 570.69 516.37 612.46 585.24

Notes:
(a) kW At Full Design Capacity
(b) NSF = No Supplemental Firing; SF = Supplemental Firing
(c) Power Consumed by the air and oxidant compressors less power recovered from the expander.
(d) 85 to 88 % of this power demand is attributable to the Cooling Water System pumps and fans.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 9
PROCESS MANUAL APPENDIX
DATE 08-94

6.4.2 Other

In addition to the cost data base developed in the eighties, the costs of various
process units have been developed recently based on:

a. Vendor quotes
b. Priced equipment data sheets
c. Priced equipment list
d. Costs of package units

These data points can be effectively utilized to develop the capital cost estimate.
With the assistance of the estimating engineer, the reference sources can be
identified and new equipment or unit capacity factors can be developed. These
factors will be used by the estimating engineer to develop the total plant
investment.

6.5 SALES QUALIFICATION DOCUMENTS

(TBD)

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 10
PROCESS MANUAL APPENDIX
DATE 08-94

6.6 LIST OF NORMALIZED UNITS

Unit No. Description

Volume I - On Site Units

1B Coal Receiving, Covered Storage and Reclaiming

1C Railroad Car Unloading of Coal
2A Coal Prep, Wet Screening (1-1/2" x 1/8" Lurgi)
2B Coal Prep, Dry Screening (2" x 1/4" Lurgi) (hold)
2C Coal Prep, Wet Grinding (Texaco)
2D Coal Prep, Dry Grinding (Westinghouse)
2E Coke Prep, Dry Grinding (Shell)
2F Coke Prep, Dry Screening (4" x 1/4" Lurgi)
2G-1 Coke Prep, Wet Grinding (Texaco) Delayed Coke
2G-1 Coke Prep, Wet Grinding (Texaco) Fluid Coke
3A Ash Handling (Sasol)
3B-1 Texaco Ash Handling - Radiant Gasifier
3B-2 Texaco Ash Handling - Quench Gasifier
3C Ash Handling (Westinghouse)
3D Ash Handling (Shell)
4A Fluidized Bed Drying of Coal
4B Simultaneous Drying and Grinding of Coal
10A Gasification (Lurgi)
10B-1 Texaco Gasification - Radiant Gasifier
10B-2 Texaco Gasification - Quench Gasifier
10C Gasification (Westinghouse)
10D Gasification (Shell)
10E-1 Texaco Gasification, Particulate Recovery and Recycle, Radiant Gasifier
10E-2 Texaco Gasification, Particulate Recovery and Recycle, Quench Gasifier
11A Gas Cooling (Lurgi)
11B-1 Texaco Gas Cooling, Radiant Gasifier
11B-2 Texaco Gas Cooling, Quench Gasifier
11C Gas Cooling (Westinghouse)
11D Gas Cooling (Shell)
11E-1 Texaco Gas Cooling (Ambient), Radiant Gasifier
11E-2 Texaco Gas Cooling (Ambient), Quench Gasifier
12A Rectisol (Non-Selective)
12B-1 Rectisol (Selective) - Lurgi (containing naphtha)
12B-2 Rectisol (Selective) - Gas is free of naphtha

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 11
PROCESS MANUAL APPENDIX
DATE 08-94

LIST OF NORMALIZED UNITS (Continued)

Unit No. Description

Volume I - On Site Units

12C-1 Selexol (Non-Selective) - 300 psig pressure

12C-2 Selexol (Non-Selective) - 600 psig pressure
12D-1 Selexol (Selective - gas at 800 psig)
12D-2 Selexol (Selective - gas at 300 psig)
12E Rectisol II
13 Gas Liquor Separation (Lurgi)
14 Tar Distillation
15 Coal Naphtha Hydrogenation
16 Phenosolvan

Volume II - On Site Units

17A Ammonia Recovery (CLL)

17B Ammonia Recovery (Phosam)
17C Ammonia Recovery (Cyam)
18A Sulfur Recovery (Unisulf)
18B Sulfur Recovery (Stretford)
18C Sulfur Recovery (Claus)
18D Sulfur Plant Tail Gas Treating Unit (Scot)
18E Feed Gas Concentration Prior to Sulfur Recovery (Adip - Scot)
18F Sulfur Recovery (Selectox)
18G Beavon-Unisulf Tail Gas Treating Unit
18H COS Hydrolysis of a CO2 Rich Stream
18I Sulfur Recovery (Selectox, Beavon, Unisulf)
19A Sour Shift and Shifted Gas Cooling - Lurgi
19B Sour Shift and Shifted Gas Cooling - Texaco - (other gasification licensors)
20 Synthol
21A Autothermal Reforming
21B Tubular Reforming
22 CO2 Removal (Benfield)
23 C2 Recovery
24 Ethylene Plant (Mixed C2 Feed)
25 Hydrogen Production
26 Catalyst Reduction

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 12
PROCESS MANUAL APPENDIX
DATE 08-94

LIST OF NORMALIZED UNITS (Continued)

Unit No. Description

Volume I - On Site Units

27 C5/C6 Isomerization

28 Creosote Hydrogenation
29 Light Oil Fractionation
30 Naphtha HDT and Platformer
31 Continuous Catalyst Regeneration
32 Catalytic Condensation & LPG Recovery
33 Poly Gasoline HDT
34 Decant Oil Vacuum Distillation
35 Distillate HDT with DSC
36 Primary Separation
37 Carbonyls Recovery
38 Alcohols Recovery
39 Alcohols Recovery (Fuel Blends)

Volume III - On Site Units

60A Methanol Synthesis (ICI)

60B Methanol Synthesis (Lurgi)
61 MeOH Purge to SNG
62A Monsanto Prism - Case A
62B Monsanto Prism - Case B
62C Monsanto Prism - Case C
63A MeOH Purification (Complete Dewatering)
63B MeOH Purification (Chemical Grade)
64A MTG Synthesis (Mobil)
64B MTG Synthesis (Lurgi)
65 MTG Fractionation
66 HF Alkylation
67 Heavy Gasoline Treating
68 LPG Drying
69A GCC - Texaco
69B GCC - Westinghouse
69C GCC - Shell
69D Gas Turbine Air Chiller

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 13
PROCESS MANUAL APPENDIX
DATE 08-94

LIST OF NORMALIZED UNITS (Continued)

Unit No. Description

Volume I - On Site Units

69E Fuel Gas Saturator

70A Methanation (SNG Production)
70B-1 Methanation for NH3 or H2 Plants at High Pressure
70B-2 Methanation for NH3 or H2 Plants at 400 psig
71 SNG Purification & Compression
72 H2 Purification by PSA
73 Ammonia Synthesis
74 Nitrogen Wash
75 Ammonia Absorption Refrigeration Unit
76 Bulk Acid
77A Solvent Extraction - Coal Naphtha (Lurgi)
77B Solvent Extraction - Coal Naphtha (UOP)
78 Butene Isom/HF Alkylation
79 Lurgi Liquids POX
90A Propylene Refrigeration Unit
90B Ammonia Absorption Refrigeration for use at 25 oF
90C Ammonia Absorption Refrigeration for use at _ 50 oF

Volume IV - Utility and Off Site Units

40 Oxygen Plant
41 Air and N2 Systems
42 Fuel Gas
43A Steam System, Conventional, Pulverized Coal Feed
43B Steam System, Atmospheric Fluidized Bed Combustion
Bubbling Bed Type (1,500 psig superheated steam)
43C Atmospheric Fluidized Bed Boiler, Circulating Bed Type (2,400 psig steam)
43D Atmospheric Fluidized Bed Boiler, Circulating Bed Type (1,500 psig steam)
43E Steam Superheater, 1,500 psig saturated steam feed
43F Steam Superheater, 600 psig saturated steam feed
44 BFW/Condensate
44-1 Clarifiers
44-2 Sand Filters
44-3 Reverse Osmosis

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 14
PROCESS MANUAL APPENDIX
DATE 08-94

LIST OF NORMALIZED UNITS (Continued)

Unit No. Description

Volume I - On Site Units

44-4 Thickeners
44-5 Demineralization
44-6 Sodium Zeolite Units
44-7 Potable Water Treatment
44-8 Fire Water
45-1 Process Cooling Tower (Natural Draft)
45-2 Process Cooling Tower (Forced Draft)
45-3 Utility Cooling Tower (Sasol)
46 Switchyard
47 Power Generation
47-1 Power Generation, 1,500 # 900 oF Steam 600 #, Backpressure Turbine
47-2 Power Generation, 1,500 # 900 oF Steam, Condensing Turbine
47-3 Power Generation, 600 # 750 oF Steam, Condensing Turbine
47-4 Power Generation, 120 # Steam, Condensing Turbine
48-1 Fluid Gas Desulfurization - FMC
48-2 Fluid Gas Desulfurization - Chiyoda
48-3 Fluid Gas Desulfurization - Wellman Lord
48-4 FGD Sludge Disposal
49 Area Substations
50 Interconnecting Pipeway
51 Flare Zone and Flares
52 Waste Water Treating
52-1 Biox Treater, Clarifier, and Filters
52-2 Biox Sludge Incineration
52-3 Activated Carbon Treatment
52-4 Ion Exchange
52-5 Sanitary Waste Treatment
52-6 Activated Carbon Combined with Biox and Wet Air Oxidation
52-7 Clean Storm and Oily Water System
53 CO2 Compression
54 Site Preparation
55 Fencing, Roads, etc.
56 Tank Farm
57 Dispatch

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997
 ` FLUOR DANIEL
SECTION 6.0
SYNGAS GENERATION
PAGE 15
PROCESS MANUAL APPENDIX
DATE 08-94

LIST OF NORMALIZED UNITS (Continued)

Unit No. Description

Volume I - On Site Units

58 Underground Piping
59A Control Rooms
59B Miscellaneous Buildings, Shops, Warehouses, etc.

K:\WRK090\037\345\MANUALS\SYNGAS\009-06.SAM-05/13/1997