coal m+e balance

8/16/2019 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


2/16

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


4/16

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


9/16

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


13/16

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 .


14/16

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.

coal m+e balance

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