COAL M+E BALANCE
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Transcript of COAL M+E BALANCE
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Section 4
MATERIAL AND ENERGY BALANCES
HE - H-COAL LIQU EFAC TION PROCESS, ILLINO IS COAL
~Ii M a t e r i a l S u m m ar y a n d Product Inspection
~, 4-I presents a tabu latio n of the feed an d prod uct streams for the
il liquefaction plant, Il linois Coal Case. The majo r produ cts con sist of
line, turbine fuel, d istill ate fuel oil, and liq uid propan e and butane.
gasoline blend is prepared by splitting the light naphtha from the raw
tha, hydrotreating and reforming the bottoms, and blending the light
tha and reformate. The turbi ne fuel is upgr aded by hydr otre atin g but the
illate fuel oil requires no further treatment to meet fuel grade
ificat ions.
e 4 - 2 , Product Inspection, shows typical proper ties of the gasoline
~ blend and fu e l s . These properties we re formulated from specifications
o f liquid
fu l
products furnished by EPRI and from }{-C oal product
~,j characterization data reported by HRI.
T h e r m a l E f f i c i e n c y
-
C a s e H E
The overall thermal e ffic iency of the coal liq uefac tion proce ss is defin ed as
the sum of the higher heating values of the products and by-products divided
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The electri cal energy requir ed to run conveyors pumps and air fans and the
p o w e r l o ss i n c o m p r e s s o r s a r e e x p r e s s e d a s 3 4 1 3 B t u /k W h . T h e h e a t e n e r g y
w h i c h i s t r a n s f e r r e d t o p u m p e d l i q u i d s h a s n o t b e e n c o n s i d e r e d .
M i s c e l l a n e o u s l o s s e s a c c o u n t f o r a b o u t 1 p e r c e n t o f t h e t o ta l e n e r g y i np u t .
T h e y r e s u l t f r o m a p p r o x i m a t i o n s u s e d f o r c a l c u l a t i n g v a r i o u s h e a t l o a ds .
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p
V
L
T a b l e 4 - 1
F E E D A N D P R O D U C T S U M M A R Y
H - C O A L C A S E B E
Feed Streams
As Received Co al (Illinois No. 6)
Oxygen (as 100 0 z)
Raw Water
Product Streams
s t / s d
2 1 , 8 9 1
4 , 9 1 8
5 5 , 1 7 6
i b / h r
1 , 8 2 4 , 2 4 3
4 0 9 , 8 2 5
4 , 5 9 8 , 0 0 0
Hydrocarbons bbl /sd a lb /h r
Gasoline Blend 16 010 184 779
Turbine Fuel 27 393 364 400
Distillate Fuel Oil 6,880 I07,581
Propane 7 175 52 857
B u t an e 4 , 6 5 8 3 9 , 9 3 7
N o n - B y d r o c a r b on s s t / s d i b / h r
Ammonla 222 18,498
Phenols 50 4,206
Sulfur 664 55,34 0
O t h e r s t / s d i b / h r
S l a g , A s h , S o o t t o D i s p o s a l ( ~ ) 2 , 2 5 3 1 8 7 ,7 5 6
F u e l G a s t o I n t er n a l U s e 1 , 8 7 2 . 6 1 5 6 , 0 5 4
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T a b l e 4 - 2
P R O D U C T I N S P E C T I O N
H - C O A L I L L I N O I S ) - C A S E H E
E S T I M A T E D )
G r a v i t y A n a l y s i s W t ~ R . O . N.
A P I S p . G . S N ~ C l e a r
G a s o l i n e B l e n d c
L i g h t N a p h t h a 7 7 . 0 0 . 6 7 8 7 ~ ~ - 7 5 . 0
R e f o r m a t e 3 7 . 3 0 . 8 3 8 3 1 0 . 7 4 9 8 . 0
T o t a l G a s o l i n e 4 7 . 0 0 . 7 9 2 7 - - - 9 1 . 0
T u r b i n e F u e l 2 3 . 5 0 . 9 1 2 9 0 . 0 1 O . 1 1 0 . 7 0 -
D i s t i l l a t e F u e l O i l 0 . 4 1 . 0 7 3 0 . 0 8 0 . 7 7 . 9 3 -
L e s s t h a n I p p m w t )
b
R e f : Upgrading Coal Liquids FE-2566-12 March 1978 Table 11 Period 5
Light Naphtha 4 650 bbl /s d Reformate 11 360 b bl /s d
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Table 4 3
T H E R M A L E F F I C I E N C Y C A L C U L A T I O N
H - C O A L - C A S E H E
is
F l o w R a t e
i b / h r
1 , 6 0 5 , 3 4 4
Heat Output~ Fuel
6asoline Blend
Turbine Fuel
Distillate Fuel F uel
Propane
.Butane
184,779
3 6 4 , 4 0 0
107,581
5 2 , 8 5 7
3 9 . 9 3 7
Sub-Total
Heat Output, B y-Pro ducts
Ammonia
liquid)
Phenol
Sulfur
18,498
4 , 2 0 6
5 5 , 3 4 0
S u b - T o t a l
Total
Output
H e a t o f
C o m b u s t i o n
Btu/ib B]{V)
12,669.5
1 9 , 3 7 2
1 8 , 4 8 2
17,479
2 1 , 5 0 5
2 1 , 1 0 7
9 , 1 5 2
13,997
3 , 9 9 0
T o t a l H e a t
10 Btu/hr HI{V)
2 0 , 3 3 9
3 , 5 8 0
6 , 7 3 5
1,880
1,137
843
14,175
169
59
221
449
1 4 6 2 4
E f f i c i e n c y
P e r c e n t
I00.00
17.60
3 3 . 1 1
9 . 2 4
5 . 5 9
4 . 1 5
6 9 . 6 9
0 . 8 3
0.29
1.09
2 . 2 1
7 1 . 9 0
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H e a t I n
Heal Out
Basis:
T a b l e 4 - 4
O V E R A L L E N E R G Y B A L A N C E
C A S E B E
60°F, water as liquid, 3413 Btu/kWh
106 Btu/h__Kr
Coal, H]{V
S e n s i b l e H e a t C o a l , A i r, W a t e r
input Total
2 0 , 3 3 9
9 2
H-Coal Liquids, B]{V
By-Products, KHV
S e n s i b l e H e a t i n P r o d u c t s B y - P r o d u c t s
P o w e r E x p o r t
P r o d u c t s B y - P r o d u c t s S u b t o t a l
C o o l i n g D u t i e s ( A ir W a t e r )
E n e r g y L o s s e s
F l u e G a s W a t e r V a p o r F r o m C o a l
D r y i n g
F l u e G a s F r o m P o w e r G e n e r a t i o n
S e c t i o n
1 4 1 7 5
4 4 9
3 0
1 4 6 5 4
3 3 1 4
378
4 2 3
P e r c e n t
1 0 0 . 0 0
7 1 7
1 6 2
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2
j
i
HW - H-COAL LIQUEFACTION PROCESS WYODAK COAL
11 Material S~lmarv and Product In sp ec ti on
e 4-5 presents a tabulation of the feed and product streams for the
F-Coal liquefaction plant Wyoda k coal case. The major products consist
of gasoline,
turbine fuel and distillate fuel oil. The gasoline blend
is prepared by splitting the light naphtha from the raw naph tha hydro-
treatin~ and reforming the bottoms and blendin g the light naphtha and
reformate. The turbine fuel is upgr aded by hydr otre atin g but the disti llate
fuel oil requires no f urther treat ment to meet fuel grade specif ication s.
I Table 4 - 6 Product Inspection shows typical proper ties of the gasoline
blend and fu el s. These properties were derived fro m specifications of liquid
fuel products furnished by EPRI and from H-Coal pr oduct character ization data
reported by ttRI.
The~lal E ff ic i en cy - Case HW
The ov era l l thermal ef f i ci en cy fo r th e H-Coal pro cess using Wyodak coal
i s 60.9 perc ent ( I~V) . Thermal e f f ic i enc y ca l cul a t i ons are shown in Table
4-7. Excess power produced from excess fu el is cr ed it ed at 3,413 Btu/kWh.
Heating values of gasoline turbine fuel and distillate fuel oil were
derived front HRI data for the H-Coal process. Heatin g values for by-products
were obtained from publish ed tables.
Ene_~y Balance
-
Case HW
Table 4-8 prese nts an overa l l energy ba lance fo r the H-Coal l iq uef ac t ion
process, Wyodak case.
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i
T a b l e 4 - 5
F E E D A N D P R O D U C T S U M ~ L E R Y
H-COAL - CASE }{W
F e e d S t r e a m s
As Receiv ed Coal Wyodak)
Oxygen (a s 100 0 2 )
R a w W a t e r
s t / s d
3 0 , 9 6 0
5 , 1 3 8
5 1 , 8 3 4
I b / h r
2 , 5 8 0 , 0 0 0
4 2 8 , 1 4 2
4 , 3 1 9 , 5 0 0
P r o d u c t S t r e a m s
H y d r o c a r b o n s
G a s o l i n e B l e n d
T u r b i n e F u e l
D i s t i l l a t e F u e l O i l
N o n - H y d r o c a r b o n s
Ammonia
Phenols
S u l f u r
b b l / s d a
2 1 , 7 7 2
2 5 , 8 8 0
3 , 7 4 3
s t / s d
i b / h r
2 5 7 , 3 5 5
3 2 7 , 5 7 9
5 8 , 3 2 7
i b / h r
162 13,476
2 4 2 , 0 0 0
194 16,161
O t h e r s t / s d I b / h r
1,716 143,025
3 , 3 3 2 2 7 7 , 6 2 9
S l a g, A s h, S o o t t o D i s p o s a l M F )
F u e l G a s t o I n t e r n a l U s e
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API
Gasoline Blend c
Light N~iphtha 73.7
R e f o r m a t e 3 7 . 3
Total Gasoline 43.1
Turbine Fuel 31.1
Disti llate Fuel Oil 0.9
T a b l e 4 - 6
P R O D U C T I N S P E C T I O N
H-COAL (WYODAK) - CASE HW
(ESTIMATED)
G r a v i t y A n a l y s i s W t R . O . N.
Sp.G. ~ N H Clea r
0.678 7 ~ ~ - 75.0
0.8383 I0.74 98.0
0.8104 - - - 94.0
0.8702 0.01 0.10
1 2 5 o
1 . o 6 1 o.o3 0.46 9.41 -
a Less t ha n i ppm wt)
b
Ref: Upgrading Coal Liquids, FE-2566-12, March 1978, Table 11, Period 5
c Light Naphtha 3,982 bbl/sd, Reformate 17,790 bbl/sd
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Table 4-7
T H E R M A L E F F I C I E N C Y C A L C U L A T I O N
H - C O A L - C AS E H W
Heat Input
Coal, Wyoda k MY)
Heat Output, Fuel
G a s o l i n e B l e n d
T u r b i n e F u e l
D i s t i l l a t e F u e l O i l
S u b - T o t a l
F l o w
ate
ib/hr
1 8 0 5 9 9 9
257,335
327,579
58,327
H e a t o f
C o m b u s t i o n
B t u / I b B H V )
1 1 , 4 2 0 . 6
19,609
18,958
17,620
T o t a l H e a t
106 Btu /hr BI~V)
2 0 , 6 2 6
5 , 0 4 6
6,210
Lo 8
1 2 , 2 8 4
E f f i c i e n c y
P e r c e n t
I00.00
24.46
30.11
4 . 9 8
59 55
Heat Output, By-Produc ts
Ammonia liquid)
Phenols
S u l f u r
S u b - T o t a l
P o w e r E x p o r t
Total Output
13,476
2,000
16,161
18,572 a
9 152
13 997
3 990
3 413b
123
28
64
215
63
1 2 5 6 2
0.60
0.14
0.31
1.05
0.30
60.90
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In
Basis:
T a b l e 4 - 8
O V E R A L L E N E R G Y B A L A N C E
CASE IiW
60°F, water as liquid, 3413 Btu/ kWh
1 0 6 B t u / h r P e r c e n t
Co al , ILh V
Sensible Heat Coal, Air, Water
I n p u t T o t a l
2 0 , 6 2 6
102
I00.00
t Out
H - C o a l L i q u i d s , K H V 1 2 , 2 8 4
By-P rodu cts, H]{V 215
S e n s i b l e H e a t i n P r o d u c t s & B y - P r o d u c t s 5 4
P o w e r E x p o r t 6 3
P r o d u c t s & B y - P r o d u c t s S u b t o t a l
Coolin g Duties (Air & Water)
12,616
4 , 2 2 6
E n e r g y L o s s e s
F l u e Gas & W a t e r V a p o r F r o m C o a l
Drying 1,051
F l u e G a s F r o m P o w e r G e n e r a t i o n
S e c t i o n 5 7 1
F l u e G a se s F r o m P r o c e s s F u r n a c e s 6 7 3
60.9
2 0 . 4
i i:
J t
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C A S E C M - C O A L T O M E T H A N O L , I L L I N O I S C O A L
O v e r a l l M a t e r i a l S u m m a r y a n d P r o d u c t I n s p e c t i o n
T a b l e 4 - 9 p r e s e n t s a t a b u l a t i o n o f t h e f e e d a n d p r o d u c t s t r e a m s f o r t h e
c o a l t o m e t h a n o l p l a n t b a s e d o n I l l i n o i s No . 6 c o a l a s f e e d s t o c k . T h e p l a n t
p r o d u c e s f u e l g r a d e m e t h a n o l ( 9 8 + w e i g h t p e r c e n t ) a s t h e p r i n c i p a l p r o d u c t
a n d s u l f u r f l a k e s a s a b y - p r o d u c t .
N o c o a l f i r e d b o i l e r s a n d s u p e r h e a t e r s a r e u s e d i n t h i s d e s i g n ; a l l t h e
c o a l f e e d g oe s t o t h e g a si f i e r s . N i n e o x y g e n p l a n t s a t a c a p a c i t y o f
a p p r o x i m a t e l y 2 4 0 0 t o n s p e r d a y e a c h a r e r e q u i r e d t o s a t i s f y t h e g a s i f i e r
needs.
T a b l e 4 - 1 0 p r e s e n t s a t y p i c a l a n a l y s i s f o r f u e l g r a d e m e t h a n o l .
T h e r m a l E f f i c i e n c y
T h e o v e r a l l t h e r m a l e f f i c i e n c y f o r t h e c o al t o m e t h a n o l p l a n t u s i n g I l l i n o i s
N o. 6 c o a l i s 5 5 . 0 p e r c e n t o n a n H I I V b a s i s a s s h o w n i n T a b l e 4 - 1 1 . H e a t i n g
v a l u e s f o r p r o d u c t a n d b y - p r o d u c t s t r e a m s a r e t a k e n f r o m p u b l i s h e d d a t a.
E n e r s y B a l a n c e
T a b l e 4 - 1 2 p r e s e n t s a n o v e r a l l e n e r g y b a l a n c e f o r t h e c o a l t o m e t h a n o l
p r o c e s s
T h e e n e r g y c o n t e n t o f s t r e a m s e n t e r i n g a n d l e a v i n g t h e p l a n t b o u n d a r y is
e x p r e s s e d a s t h e s u m o f t h e f o l l o w i n g :
• T h e s t r e a m s h i g h e r h e a t i n g v a l u e
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i
T a b l e 4 - 9
F E E D A N D P R O D U C T S U M M A R Y
C O A L T O M E T H A N O L - C A S E C M
F e e d S t r e a m ~
A s R e c e i v e d C o a l ( I l l i n o i s N o . 6 )
O x y g e n ( a s | 0 0 O e )
R a w W a t e r
P r o d u c t S t r e a m s
M e t h a n o l a s 9 8 . 2 9 ( w t)
S u l f u r
S l a g , A sh , S o o t to D i s p o s a l ( ~ )
F u e l G a s t o I n t e r n a l U s e
s t / s d
2 5 , 4 1 8
2 1 , 4 5 4
9 9 , 7 4 4
1 5 , 9 1 9 a
7 6 8
2 , 6 4 8
2 , 3 0 6
a M e t h a n o l [ u el = 1 1 1 , 8 7 0 b b l / s d ( a c t u a l ) o r 5 2 , 2 0 9 F O E b b l / s d .
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T a b l e 4 - 1 0
~ £ T H A N O L P R O D U C T A N A L Y S I S
C O A L T O M E T H A N O L - C A S E C M
C o m p o n e n t
Low Boilers, ~ (wt)
High Boilers, (wt)
Water, (wt)
M e t h a n o l , ~ ( w t )
S p e c i f i c G r a v i t y @ 6 0 ° F
H i g h e r H e a t i n g V a l u e ( }{ HV ) B t u / i b
0 . I 0 0 . 1 2
0.05 - 0.08
1.71
98.29
0 . 8 1 3
9 , 5 9 3
a I n c l u d i n g h i g h a n d l o w b o i l e rs .
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i
Table 4-11
T H E R m a L E F F I C I E N C Y C A L C U L A T I ON
COAL TO METHANOL - CASE CM
T
H e a t I n p u t
Flow Rate
Ib/hr
C o a l ~ )
H e a t O u t p u t
Methano l
S u l f u r
Heat of
Combustion Total Heat
Btu/ib HHV) 10 6 Btu/hr HHV)
E f f i c i e n c y
Percent
1 , 8 6 4 , 0 0 0 1 2 , 6 6 9 . 5 2 3 , 6 1 6 1 0 0 . 0 0
1 , 3 2 6 , 5 9 4 9 , 5 9 3 . 0 1 2 , 7 2 6 5 3 . 9
6 4 , 0 0 0 3 , 9 9 0 . 0 2 55 1 . 1
12,981
otal Output
5 5 . 0
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T a b l e 4 - 1 2
ENERGY BALANCE - COAL TO METHANOL
CASE CM
Basis: 60°F, water as liquid, 3413 Btu/kWh,
Sensible
Heat In Btu)
Coa~ a
ir
Water
12,669.5
35.3
T O T A L
12,669.5 35.3
Heat Out Btu)
M e t h a n o l 6 , 8 2 7 . 2
Sulfur 136.8
A i r C o o l i n g
C o o l i n g T o w e r
G a s i f i e r L o s s
02 Plant Waste Gas
Sulfur Plant Flue Gas
P o w e r B l o c k L o s s
S u p e r h e a t e r L o s s
Steam Loss
M o t o r L o s s
W a s t e W a t e r 5 . 0
CO 2 Vent 72.5
17.1
3.5
621.2
28.0
14.4
54.0
29.0
12.8
TOTAL 7,041.5 780.0
i Ib MF Coal @ 60°F
L a t e n t
8 2 6
8 2 . 6
4 , 1 5 2 . 4
72.3
6.5
108.6
4 , 3 3 9 . 8
R a d i a t i o n
363.7
13.4
120.7
497.8
Power
31.9
96.4
128.3
Total
12,669.5
117.9
0.0
12,787.4
6,844.3
140.3
621.2
4,152.4
363.7
I00.3
20.9
31.9
176.0
120.7
96.4
34.0
85.3
12,787.4
a Total MF coal = 1,863,965 ib/hr.
b
Air input @ 88°F, 14.4 psia, and 75°F wet bulb.