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DOW.Kl27339 . . 4065 (DE93950097 I I )
ENCOAL Mild Coal Gasification Project Public Design and Construction Report
Topical Report
December I994
Work Performed Under Contract No.: DE-FC2I-90MC27339
For For U.S. Department of Energy U.S. Department of Energy Office of Fosrll Office of Fosrll Ener Ener Morgantown Energy Morgantown Energy Y Y ethnology Center ethnology Center Morgantown, West Virginia Morgantown, West Virginia
BY ENCOAL Corporatlon Gillette, Wyoming
DISCLAIMER
This rqnsi wm prepad m an account of wotk spomored by aa agency oftbe United Staes Govcmtnmt. Neither the United Swcs Govemntmt nor ny agency thereof, nor any of their employees. makes any wxmnty. exprcsr ci implied. ot L~U~CI any kgal liability a responsibility for the acamcy. compktettcss. or uscfulmv of any Ittfamtuion. apparatus. pmduot. or pmcw disclowd, or represents that its use would not infringe privately owned rights. Ref- herein ta any spccifii commercial pmduct, pmccis, DI service by trade name. Imdctnark, matufacturer, w Mhmviw does not necesswily ccastltuto or imply its endorsement. recommendation, or lawring by the United States Govetnmcnt or any agency tbcrcof. Ihe views and opinions of authws cxpresxd herein da not nccesnarily slate or reflect those of the United States Govemmatt or any lymcy thereof.
This nporl has been reproduced directly from the best availahlc copy.
Available to DOE and DOE contractors from the Oftice of Scientific and Technical Information, 175 Oak Ridge Turnpike, Oak Ridge. TN 37831: prices availabIc at (615) 576-8401.
Available to tlte public from the National Technical Information Service. U.S. Dq~anment ofCommerce, 5285 f‘ort Royal Road, Springtkid. VA 22 161; phtmc ordets accepted at (703) 487-4650.
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DOEIMCJ27339 -- ‘1065 (DE9500971 I)
DlstdbuUon cltc&xy UC-109
ENCOAL Mild Coal Gaslflcatlon Prolect Public Design and Construction Report
Topical Report
Work Performed Under Contract No.: DE-K2 l-9OMC27339
For U.S. Department of Energy
Office of Fossil Energy Morgantown Energy Technology C-enter
P.O. Box 880 Morgantown, West Virginia 26507.0880
ENCOAL ?orporatlon P.O. Box 3038
Clllette, Wyoming
December 1994
ENCOAL MILD COAL GASIFICATION PROJECT PUMJC DESIGN ANI CONS’IRUCTION RFmRT
TABLE OF CONTENTS
LJSTOFAPPENDICES: ...................................... x
LISTOFFGUIUES ......................................... xi
LISTOFTABLES .......................................... xiv
GLOSSARY .............................................. xv
1.0 SUMMARY .......................................... 1
2.0 INTRODUCTION ...................................... I
3.0 PROJECTBACKGROUh’D. ............................... I
4.0 OVRRVIRWOFPROCRSS ................................ 3
5.0 OVERVIEW OF DESIGN CONSIDERATIONS .................... 9 S.1 CIVILDESIGN ................................... 9 5.2 MECHANICAL DESIGN ............................. 17 5.3 ELECTRICAL AND INSTRUMENTATION DESIGN ............ 28
6.0 MAJOR EQUIPMENT FUNCTIONS AND DESCRIPTIONS .......... 34
:*: 6:3 6.4 6.5 6.6
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El 6:ll 6.12 6.13 6.14
FEEtiCOALSYSTEM ............................... 34 COAL DRYER AND CYCLONE COALPYROLYZERANDCYCL&$::::::::::::::::::::: z QUENCH TABLE .................................. 42 PDFCOOLER .................................... 42 PDF FRODUCT SYSTEM ............................. 44 QUENCHTOWER ................................. 44 ELECl’ROSTAmC PRECIPITATORS ...................... 47 COAL DERIVED LIQUID (CDL) HANDLING SYSTEM ......... 47 DRYERBLOWER .................................. 52 PYROLYZEI),BLOWJ% .............................. 52 COMBUSTORS ................................... PURGE GAS TREATMENT DUSTSCRUBBERS ..... . . . . . . . . . . . . . . . . . .
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7.0 UTILJTIES .......................................... al 7.1 STEAMSYSTEM .................................. 60 . 7.2 INSTRUMENT AND PLANT AIR ........................ 7.3 COOLING WATER.. ............................... zi 7.4 OLYCOUWATERCIRCULA~GSYSTEM ................. 61 7.5 PGTABLEWATBR ................................. 61 7.6 FIREWATER ..................................... 63 7.7 NITRGGEN ...................................... 63 7.8 NATURALGAS ................................... 64
8.0 CONSTRucrnON ...................................... & 8.1 CONTRACTING METHODOLOGY ....................... 8.2 CONTRACTPACKAGES.. ........................... zi 8.3 EARTHWORK, SURVEYING AND TESTDIG ................ 66 8.4 STfXlAGESILOS .................................. 67 8.5 PDFPLANT ..................................... 69
8.5.1 Foundations ...... ‘, .......................... 72 8.52 Undergmund pipin& Conduit and Equipment Foundations ..... 74 8.5.3 Mechanical Ercdtion
8.6 SCREENING BUILDING ............................. 85 8.7 ABOVEGROUNDFIPING ............................ 87 8.8 ARCHlTECTURALBUILDlNGS ........................ 87 8.9 ELP,CTRICAL AND INSTRUMENTATION .................. 89 8.10 MISCELLANEOUS ................................. 92
9.0 ENVIRONMENTAL CCINCERNS ............................ 96 AIR POLLUTANTS
;:: WATBREFFLUENTS’::::::::::: ........................................ 96
96 9.3 SOLlDlHAZARDOUS WASTE GENERATION ................ 97
10.0 SAFRTYPRACTICES ................................... 10.1 INDUSTRIAL HYGIENE ............................. ii 10.2 PHYSICAL HAZARDS .............................. 98 10.3 CONSTRUCTION SAFETY PRACTICES ................... 98
.. 11.0 CONCLUSIONS ....................................... 100
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This “proprietary data” furnished under Cooperative Agrosmont DE-FC21-9OMC27339.0 with tho United States Dopattment of Energy may bc duplicated and used by the Govanmeat with the express limitations that tho “proprietary data* may not be disclosed outside the G-mau or be used for purposes of manufacture without prior pemirshx~ of the FWticipant, except that further disclosure or use may be made solely for the following purposes:
(1) This ‘proprietary data” may be disclosed for evaluation purposes under the restriction that the “proprietary data” be retained in confidence and not be further disclosed;
(2) This “proprict*,-y data” may be disclo& to other contmctom participating in the Govomment’s program of which this Cooperative Agreement is a part, for information or use in connection with the work performed under theso contmcts and under the rcstric5on that the “proprietary data” bc rztaincd in cordidence and not be funher dlsclooad: or
(3) This “pmprietary data” may be used by the Govemmcnt or others on its behalf for emergency repair or overhaul work at the Facility under the. restricrion that the “proprietary data” be retained in confidence and not be further disclosed.
Appendix B Pages Bl - B3 Appendix C Pages Cl - C3 Appendix D Pages Dl - D2 Appendix E Pages El - B2
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LIST OF APPENDICES
AppsndixA . . . . . . . . . . . . . . . . . . . . . . . . . . CivilxndMcchani~Layoutr
Appendix B .*,...,............................. c0d Wnr propriertiy)
AppcndixC . . . . . . . . . . . . . . . . . . . . . . . CoxlPyrolysisxndCDLBecovuy WJPriCtocy)
AppcndixD . . . . . . . . . . . . . . . . . . . , . . . , , . . . , . . PurgeGasTreatment Vropfietary)
Appendix E . . . . . . . . . . . . . . . , . I , . . . . . . . . . . . . . . PDF Stabilisation (pr0pri-S)
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g2-i Figum 3:3 Figure 4.1 Figure 5.1 Figure 5.2 Figure 5.3
2:: :.i Figum 516 Figure 5.7 Figure 5.8 Fiiun 5.9 Figure 5.10 Figure 5.11 Figum 5.12 Figure 5.13 Figure 5.14 Figure 5.15 Figure 5.16 Figure 5: 17 Figure 5.18 Figure 5.19 Figum 5.20 Figum 5.21 Figum 6. I Figum 6.2 Figure 6.3 Figure 6.4 Figum 6.5 Figum 6.6 Figure 6.7 Figure 6.8 Figum 6.9 Figum 6.10 Figum 6.11 Figum 6.12 Figum 6.13 Figure 6.14 Pigum 6.15 Figure 6.16 Figum 6.17 Figum 6.18 Figure 6.19 Figure 6.20
LIST OF PTGURES
FiiMasterScWuk ................................ LLK-ationMap ..................................... : ProjectSiteLayout.. ................................ 6 Simplified Flow Dipgram .............................. 8 overall Site Plan ................................... 10 PDF Ama Site Plan ................................. 11 Sedimentation Pond aud Pumps .......................... 12 CDLStora@Area .................................. 13 PipoRaokPlan.. .................................. 14 TruokandRailLoadout ............................... I5 RawCoalSiloArea.. ............................... f6 West Elevation .................................... 18 Past Elevation ..................................... 19 NmthandSoutbElevations ............................ 20 PDF Bin Elevations ................................. 21 Screening Building EIevations ........................... 22 First Floor PDF ................................... 23 BlcvationstoThirdFloorPDF .......................... 24 PDF Flmrs Four Through Six ........................... 25 PDF Floors Seven Through Ten .......................... 26 Screening Building Floors ............................. 27 Overall One Litm Diagram ............................. 30 High Voltage Switch Gear ............................. 31 High Voltage Motor Controls ........................... 32 Low Voltage Substation ............................... 33 CoalFeedStorageSilo ............................... 35 Vibrating Feeder ................................... 35 TtipleDeckCoalScreon .............................. 36 &d CNShW ..................................... 36 Salem Coal Dryer General Arrangement ..................... 37 SalemCoalDryer .................................. 38 Sketch of the Dryer Xntomals ........................... 38 Dryer Rabbles Arrangemutt ............................ 39 DryuCyclooe .................................... 40 Typical Cyclone Design ............................... 40 Coal FineScrew Conveyor/Cooler ........................ 41 Sak.m Coal Pyrolyxor ................................ 42 SalemQuonchTable.. ............................... 43 QuenchSteamCondenmr. ............................ 43 PDFCooler ...................................... 44 GeneralhrrangementPDFCooler ........................ 45 Gamma-Metric Coal Analyar ........................... 46 Top Portion of the Quench Tower ........................ 46 SketchoftheQucnchTowertntcrnals ...................... 47 ‘&nerdArrangementQuenchTowa ....................... 46
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Figure 6.21 Figure 6.22 F&6.23 Figure 6.24 Figure 6.25 Figure 6.26 Figuto 6.27 F&we 6.28 Figure 6.29 Figure 6.30 Figure 6.31 Figure 6.32 Figure 6.33 Figure 6.34 F~UN 6.35 F~urc 6.36 xgure 7.1 Figure 7.2 Figure 8.1 Figure 8.2 Figure 8.3 Figme 8.4 Figure 8.5 Figute 8.6 Figure 8.7 Figure 8.8 F&me 8.9 Fii 8.10 Figure 8.11 Figure 8.12 Figure 8.13 Figure 8.14 FlgtltX 8.15 Figure a. 16 Figure 8.17
. . Figure 8.18 Figure 8.19 Figure 8.20 Figure 8.21 . Flgun 8.22 Figure 8.23 Figure 8.24 Figure 8.25 Figure 8.26 Figure 8.27 Figure 8.28 Figure 8.29
GeneralArrangomentESP’s ............................ 49 Top Portion of the Bleotmslatic Precipitator. .................. 50 !a?tchofELctrdc~ ......................... 50 CDLStotxgeTanks ................................. CDL Meter ...................................... z: Dryer Recirculation Blower ............................ Pyrolyzor Reoircuiation Blower .......................... :: Combustors ...................................... 54 General Anangemau Combustor ......................... 55 Sketch of the Combustor Internals ........................ 56 Combustion Air Blowers .............................. 56 Desulfuriration Unit ................................. 57 Purge Gas Treatment Internals ........................... 57 Temporary Evaporation Pond ........................... 58 Dust Scrubber at Scmening Facilities ....................... 59 DustScmbheratCosiFeedsllo .......................... 59 CDLCoolor ...................................... 62 Fin Fan Glycol Cooler ............................... 62 Construction Schedule ................................ 65 RawCoalSiloSlipForm.. ............................ 68 Completed Raw CoalSilo ............................. 69 Equipment Delivery Goals ............................. 70 Construction Schedule ................................ 71 PDF Building Excavation .............................. 72 PDF Buildin Rebar Mats ............................. 73 PDF Building Foundation Pour .......................... 73 PDF and Screening Building Foondations .................... 74 Backtilled PDF Building Foundation ....................... 75 Undorgmund Piping and Equipment Foundations in Progress ........ 75 Completed Bquipment Foundations and Floor Slabs .............. 76 Quench Column and PDF Quench Table. .................... 78 PDF Quench Table and 3rd Floor In Place ................... 78 Blowers, BSP’s and l-Iorizonbl Scrubber ln Place ............... I9 WestViewofBSP’sandHoriaonlaScrubber ................. 79 PyrolyxorAssembly ................................. 80 PyrolyxwInPlaco.Roofat1O6’ ......................... 81 Pyrolyw Cyclone Installed (Center) ....................... 81 Startof6thFloorDeckandSteel ......................... 82 Dryer, Inlet Duct and Outlet Duct ........................ a2 Dryer In Place Awaiting Cyclone ......................... 83 Dryer Cyclone and Sttuctutnl Steal in Place ................... 83 All Equipment and Structural Steal Complete .................. 84 InstallationofRawCoalS-BeltandRoof .................... 84 AerialViewofCompletcdPlant(Ceuter) .................... 85 Screening Building Prior to Siding ........................ 86 Completed Screening Building ........................... 86 Above Ground Piping ................................ 87
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Figure 8.30 Tank Farm Piping .................................. Figum8.31 CDLTrucklTninLoadoutRack ......................... Figme 832 MCCBuildiigand4SOVSubstatioo ....................... 89 Figure 8.33 Control Building Near Compleiton ........................ Figure 8.34 Original Control Room Layout .......................... ii Figure 8.35 Coolll Water Pump House ............................ 91 Figure 8.36 Cooling Water Intake . Existing Triton Pond .................. 91 Figures.37 CDLStorageTanksUnderConstructia. ..................... 93 Figure 8.38 Rail Siding Under Ccmsmtction .......................... 93 Figure 8.39 Monthly Physical Percent Complete ....................... 94 Figure 8.40 Manpower Loading Chart .............................. 95 Figure10 .l LortTimeIncidentRales .............................. 99 FigureA .I BNCOALFacilitiesLayout ............................. A-l Figure A.2 Control Room. .................................... A-2 FiiurcA.3 InterioroftheControlRoom ........................... .A-2 Fiiure A.4 PDF Struclure boldng Southwest ........................ A-3 Figure A.5 ENCOAL Facilities Looking Northeast ..................... A-3 Figure A.6 PDF Structure Floor Plan (Blevation loo’-6’) ................. A-4 Figore A.7 PDF Structure Floor Plan (l?levatlon 129’.6”) ................. A-5 Figure A.8 PDF Structure Floor Plan (Elevation 142’.6”) ................. A-6 Figure A.9 PDF Struclure Floor Plan (Elevation 162--O”) ................. A-7 Figure A.10 PDF Stntctute Floor Plan (Elevation 182’.6”) ................. A-8 Figure A. 11 Floor Plan (Elevations 206’.3’) .......................... A-9 Figure A.12 PDF Stmctun Floor Plan (Elevations 225’6” and 235’.6’) ........ A-10 Figure A.13 PDF Struclure Floor Plan (Elevations 260’45” and 279’.2’) ........ A-11 Figure A.14 Screening Building ................................. A-12 Figore A.15 Screening Building Floor Plan .......................... A-13 Figure B. 1 CoalDrying......................................B- 3 Figure C. 1 Pyrolysis and CDL Recovery ........................... c-3 Figure D. 1 PurgeGasTreatment ............................... .D-2 Figure E. 1 PDF Stabilimtion .................................. E-2
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LI!3T OF TABLES
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Table 6.1 purge Gas Composition ............................... 54 Table 8.1 thbcontmctors for ENCOAL Project ....................... 67 Table A.1 EquipmentList.. ................................. A-14
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ASMB BS&W Btll CDI:
2 cq DOE BNCOAL
ESP 9; ft. ft.2 HP W W in. Kellogg lb/hr LFC Technology MM Blulhr Max MSHA N4( 4 PDF PLC % PH ph Psig RPM SMC
i$ turnkey
American Society of Mechanical Engineers Basic Sedimeot & Water British Thermal Units coal Derived Liquid Methello Carbon Monoxide Carbon Dioxide U.S. Department of Bnergy ENCOAL Corporationi wholly-owned subsidiary of SMC Mining Company Electrostatic Precipitators Degrees Fahrenheit Feet Square Feet Horsepower Water Hydrogen Sulfide Inches The M. W. Kellogg Company Pounds per Hour Liquid From Coal Technology
. Million British Thermal Units per Hour Maximum Mine Safety and Ho&b Administmtion Nitrogen Oxides Oxygen Process Derived Fuel Programmable Logic Controller Percent Measure of alkalinity and acidity on a scale of 0 to 14 Pounds per Square Inch Absolute Pounds’per Square. Inch Gauge Rotations per Minute SMC Mining Company, wholly owned subsidiary of Zeigler Coal Holdiig Company, formerly Shell Mining Company Sulfur Dioxide Sulfur Oxides Subcontracting method that indudes design, fumishing and installation responsibility v01umo
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1.0 SUMMARY
qhsing,dstaikd&sQnandamrmrtiashrve~compkbdforacoal ~~emonstmtim plant whose products will have a ~igfIihntly gmater value than that of the plant feud. The plant is dosigned to process 1066 ton/day of subbituminous Power R&r Basin (PRB) low-sulfur coal feed and to produce two produets, a solid fuel and a liquid feel. lltc solid ptiuct, Process Derived Fuel (PDF), is a stabk, low-sulfbr, high-Btu fuel similar in composition and handling pmg&e.s to bituminoos coal. The liquid prodoct, Coal Derived I&rid (CDL), is a heavy, low-sulfur, liquid foel similar in pmpatks to heavy industrial fuel oil.
Sinco this is a demonstration plant, opaating flexibility was a major thetor in the process de&a. Environmental concerns. autooration, and safety pm&es wem also given a very high priority.
2.0 INTRODUCTION
This Pubhc Design Report describes the loo0 Ion per day ENCOAL mild coal gasiflmtion demonstration plant now in operation at the Buckskin Mine near Gilletk, Wyoming. The project is being cost-shared by the U.S. Department of Energy (DOE), uttdor the Ckan Coal Technology Pmgram udministemd by the Morgantown Energy Technology Center u&r Cooperative Agreomart number DE-FCZl-WMC27339.
The objective of the pmject is to demonstrate that the proprietary Liquids From Coal &PC!) todmokgy can reliably and economically convert low Btu PRB coal into a superior, high-Bht solid fuel (PDF), and an environmentally attractive low-sulfur liquid fuel (CDL). The Project’s plans also call for the production of suffcimt qua&es of PDF and CDL to permit utility companies to carry out full scale bum tests.
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While some process as well as me&ok4 de@3n was done in 1988, the umtinuoos design effotl was started in July, 1990. Civil construction was started in October, 1990; mechanical eraxkn began in May, 1991.. Viiually all of the planned design work was compkted by July 1991. Most major construction was complete by April, 1992 followed by plant testing sod commiss;oning. Plant operation began in late May, 1992. This repott covers both the. detailed design and initial construction aspects of the Project,
3.0 PROJECT BACKGROUND
ENCOAL’s patent company, Shell Mining Company (SMC), began working on upgrading low rank coal in the early 1970’s. In 1986 SMC held discussions with SO1 Inkmationsl (SGI), a technology company Lacatd in ti Yolk, California, to kam of their LFC technology. The LFC teehnokgy is a mild pyrolysis process which cooverts coal into a solid fuel and a liquid fuel. The PDF is a stable, low-moisture, low-sulfur material comparable to bituminous coal except it is more reactive during combustion. industrial fuel oil.
The CDL is similar in propertks to low-sulfur heavy
Using coal fmm the Buckskin Mine as a feed stock, SMC mtd SGI ran a se&s of pilot plart tests beginning ln 1987 in ~31’s small swle pilot plant unit loostut near Pittsburgh, PA. The km concaltmted on valious aspects of the LFC pmccls, such es dryll and pyrolyzing of coal. solids can-y over, liquid collection and process vdbks. In add&m, PDF and CDL were pmduccd for laboratory tcstlng. Sovanl diffmmt flow schcmcs and process modifications wete evaluated during thm& tests. For instance, the unit was upgtaded ti’om a 58 Lb per hour batch process to a 200 lb per hour semi-continuous process. The experimental studies were exten&d into 1988 with the following results:
(1) Scmi-oontlnuous opcratlon was achieved (2) Tc the extent possible, process vasiables were evaluated (3) Acceptabie mass balamxs were calculated (4) suff1cicnt quantities of products were produced for chamcmtistic analysis snd process
evaluation
Extensive product testing was conducted at Shell Developmeat Company’s Westhollow Besear& Center in Houston, Texas. PDF was subjected to a month-long. amwd-theclock test bum in a laboratory combustion frcility. The results showed that the PDF was a very stable prcut~a with very d&table combustion pmpcrties. The composition of CDL was analyzed for over 2tXt compounds. The usual tests to characterise the properties of fuel oils were also run on the CDL. These laboratory results, as well as tiuthcr discussions with ~rnentlal customers, led SMC to believe that the LFC technolqy held significant promise to be technologically and commercially sound. In January, 1988. SMC solicited pmposals from five major engineering companies and ultimately selcctcd The M. W. Kellogg Company (Kellogg) to (1) puform a thorough investigation of the prccess, (2) design a nominal loo0 ton&y plant, and (3) prepam a cost estimate.
To guide the design team, SMC developed the following objcotives for the demon&ratlon plant: (1) Provide products for commercial scale test bums (2) Obtain data for the dcslgn of future commercial plants (3) Demonstrate plant and process performance (4) Provide capital and operating costs data (5) Support future LFC technology licensing efforts
Given these objectives, a project team was asscmblcd and charged wlth the m.sPonsiblllty of designing the hcilities. The team developal a set of yidelina to aid the design:
(1) Kaep sadcup from the SGI pilot plant reasonable. (2) Use currently available commercial quipmeat as much as posaihle. 9) K&p the pmccss simple, postpene the r&nement of CDL. (4) Match the products to existing markets. (3) Mlnimize all releases to the environment.
Although SMC was pkamd with the results of the LFC tqhnolo8y waluation, product atmtysis, and market forecast for the sale of the products, the total cost of the project mpresonted a sixable undertaking. In 1989, SMC decided to s&r funding support from the DOE under the cL%n Coal Technology Program. ENCGAL Corporation, a wholly-owned subsidiary of SMC, WAS famed for the purposes of entering into a Cooperative A8recment wk. the DOK and of
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deal&g and constmcting the 1WO ton per day rbmonstration plant. The Coopanuve Agmuncnt with the DOE was signed on September 17, 1990. Figure 3.1 shows the Project ~~dcvclapedbyENCOALmdrmcptedbythcDOEfa~~ofdesign (Phase9 and constructinn (phase Il) of the demonstration ptuu faciE&. This Project schedule was moderately aggmssive and rquired the use of fast-tracking methods, that is the overlap of design and construction. It was felt at the time that there was some room for improvement if changes in the design could bc kept to a minimum and equipment delivuks promised by vcndon were met. Neither of these improvements occumd and it took the full effort of rll Project team members to maintain the original scbahde.
The Buck&in Mine of Triton Coal Company, another wholly-owned subsidiary of SMC, was chasm as the host location for the plant. This huge PBB surface mire is located in norlhustan Wyoming as shown on Figure 3.2. Sclectcd in part because Triton is a sister cornpatty, the Buckskin Mine had an available ske. existing roads, railroad, coal stooge and handling facilities, utilities and infinstructurc sufficient to SupptUt both the mine and ENCOAL. In addition, T&on could supply the raw coal for processing. Figure 3.3 shows the site layout for the existing Buckskin Mine facilities and the new BNCOAL Project facilities.
The sibs is surmunrkd by active coal mining opcmtions and property that will be mined in the next few years. Ocologically, the plant area is an ancient ecean bottom environment that is extremely varlabk due to its proximity to the bum zone at the subsurface outcrop of the major cad seam. Competent rock is ram and dqp in most of the plant site arca, and soil beating conditions vary from poor to Zoo0 pounds per square foot. Under the actual plant ske itself was an exception, however, and the preliminary gcotcchnical work shuwal that a s~nnad foundation was acceptable for ttm PDF plant and screening building structures. Ail other suuctmes tquired concrctc caissons of various depths. Gcogmphically, the plant site is at approximately 4100 feet elevatico and is subject tu cold w&her extremes. Although not lecated in a highly active tectonic region, the plant site is subjected daily to ncarby blasting activities in the mine. AU of these conditions were evaluated in the plant design and appropriate equipment ratings, civil designs and wintcriration were included.
The home office engineering and design group at Kellogg completed their work in July, 1991. All remaining engineering, which mostly involved review and approval of field changer, was done by ENCOAL and Kellogg Construction Inc.(KCI) on-site engineers. PieM engineering was mcm extensive on this Project bccausc the home offit engineering team was &mobllixcd before developing a totally complete duign. However, this decision proved to bn cost effective, especially considering the impact on the Project Ms&r Schedule if the field construction was delayad. With the design completed and construction in the fuul stages, commissioning and plant startup began in the 2nd quarter of 1992. Full integmtcd apcmtion was achieved at near d+aign conditions for 24 continuous hours on June 17, 1992.
4.0 OVERVIEW OF PROCESS
The LFC process is a mild gasification or pyrolysis proc-ess which involves heating of coal under csrefuhy contmlled conditions to produce gaseous compounds. Figure 4.1 shows a simplifti flow diagram of BNCOAL’s applicatim of the LFC tcohnology.
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A
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MINE LOCATION MAP EASTERN POWDER RIVER BASIN
- -=----~- Q \ I i.-
-T d If57 I---- --- .-.
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Figure 3.2 5
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Run-of-mintcoali$~ycahomUKBue~n~toa~~rlb. llteeoslfiumthisailo is rreened to remove over&e and undersire materials. The specification aml feed, 2” x 118’ ~pasWthrWghnG.4M!bL4XFrRIc!ScoalaMlyxerwhkilnlasnrm themoistum,ash. carbon, hydrogen, stdfut, and 0thC.f Contents Of the fd Cd. The Cd iS Hal fed into a perfotatcd mary gtate dryer where it is heated by a hot gas stream. 2%~ tuidena time of the coal and temperature of the inlet gas have been selected to tufttee tho moisture content of the coal without initiating chemical changes. The solid bulk temperature is controlled so that no significant amount of methane, carbon monoxide or Wbon diide is releaxed from the coal.
The solids from the dryer are then transferted to the pyrolyxer wbem the temperature of the dried coat is raised to about lOO@T by a hot reoycled gas stream. The rate of hating of the solids i.e., the inlet tempcmtum and flow rate of the hot recycled 8as atream, is catdUly contmlled because it determines the pmpetties of the solii and iiquid pmduc~. In the pyrolyxer. a chemical reaction cccurs which testsIts in the mlease of volatile 8asemm materials from the coal. Solids exiting the pyrolyse are quickly quenched to ,stop the pyrolysis reaction. They ate then cooled and transf&red to the PDF storage silo. Since the solids have no surface ttxristure and, thesefore, are likely to be dusty. a dust suppressnnt ealied h4R is added as they leave the PDF product silo as foal product.
The gas produced in the pytolyxer is aent through a cyclone for removal of pyticulates. It is then sent to a quench tower to stop any secondary teaetiw end to condense the desired Liquids. Only CDL is condensed in this step; the condensation of water is avoided. The gas stream leaving the quench tower may contain some CDL in the form of a fine mist. In order to recever the llquld mist, three eleotrostatic precipitators (RSP’s) operating in pamRet were btsteJied. The finished CDL product is pumped from the battom of the quench tower to storage.
Tlte residual (ear fmm the electrostatic precipitators is divided into three streams. Most of it is recycled directly to the pymlyzer, Some is bunted in the pyrolymr combuatnr and then mixed with the recycled gas to provide heat for the mild gpsffiuttion ration. The remainder of the gas is burned in the dryer combustor, which converts sulfur compounds to sulfur oxides (SO,) and hydrocarbons to carbon oxides (Cod. Nitrogen oxide (NOJ and carbon monoxide (CO) emissions an controlled by appropriate design of the combustor. The hot flue gas from the dtyer combustor is blended with the recycled gas from the dryer to provide heat for drying.
Tho off-gas from the dryer tlrst passes thmu8h a cyelone to remove the entrained partieulatex. It is then divided into Iwo streams. Most of it is racyclod directly to the dryer while the . remainder is treated with sodium carbonate solution in a two-sta8e scrubber system. By spraying the off-gas with sodium carbonate solution, the first stage scrubber captures the fine patticulates that escape the dryer cyclone, and the second stage sorubber removes most of the
_ sulfur oxides from the gas stream by converting it into sadiurn sultlte. l’lte sultiteisthen oxidixed into sodium sulfate. The treated gas is vented to the atmosphere thmugh a stack while the spent solution is sent into a nondiirchatging pond for evaporation.
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S.0 OVEUVXEW OF DESIGN CONSXDERKX’XO~
EorlyiothcdcJEDplPceofUls~BNCOALurdICelbsCdcvGkrpdadacumcntcrllcd the “Design w which contained the underlying pmmisas for the design of tba PDP plant and asmdatal facilldu. Site s@lXc information such as elevation, climate, wind and saow ccmdid~, rainfaN and tmtonic rtivity was Listad. Thu industry standa& to be used in the design and the governing indushy coda that must ba followed were idattiflcd. It was de&mined that the Project would fall undct the jurisdiction of the Mine Safdy And Health Administration (MSHA) due to its loation on the Buckskin Mine prapmty. lldi can&i a special set of rquinmenu for design, especiplly in the - of corl dryiy, lifting and hoisting. electrical cblssifi~tions and pcmmlbd safety prctecdor:.
Other ams covered by the Design Basis wwe the nominal capa& of the plant, namely 1000 tons feed coal per day and ~!IC ovcxdcsign ma&a for given conditions. In general, a margin of 15% over the nominal design for individual pieces of equipment was the guide4ine, but this margin was defined so that It would not be additive. A ‘Pmress Release’ document was also produced based on the description in Section 4. The Process Release contained the detailed beat and material balance for all individual pmcess stmams.
About halhay thmugh the detailed de&n effon at Kellogg, after sumcient work had been dona to describe the facilides, a Hazards of Opendons fHazOps) review was performed. A group of experts was assembled from the design team and horn external sources at Kellogg and Shell. The gmup produced a report with ncommendations for design modifications, training pmvisions and operating procedures. The HasOps recommendations wore followed camfully, and the design modifications wae implemented.
5.1 CIVIL DEXON
The category called civil design on the ENCOAL Pmjcct includes the site prepamdon, drainage. ponds, foundations and structures as wall as the architectural features of the buildings. Since the BNCOAL Project is located on an active mine site, the civil design had to be coordinatai with the mine, aspecially the drainage and ponds. Run-off from the mine v through UK. PDF plant site in several places and had to be handled. Wastewater and run-off collection ponds m combined for the mino and new facilities wherever po.ssible. At the same thna as the ENCOAL Project was in consbuction, the mine installed a major axpandon project, further unphrlzing the oeed for close coordination of the Project designs. Detailed plot plans ate shown in Figures 5.1 through 5.7.
The Civil Eaginccring gmup developed a w of guidelines for their designs. Some of the highlights were:
(I) Use a safety factor of four for btructunl desii. (2) In the absence of local building codes for the site, use standard industrial codes. (3) Enclose and heat all buildings due to the weather factor. (4) Design for wind load of 100 mph and snow load of 30 psf. (5) A ventilation system must ccal the PDF building in hot weather and exhaust noxious
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(6) Design all dw stmctu~~ for the 100 year, 24 hour eveat. (7) Use bolted connections for all fti erected joints with spcirlly Qigncd torque
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During the 1988 pmlimiaary design studio by Kelloop, a conceptual Iayout of the PDF plant structum was develupcd. One of the first tasks for the Civil Faginceriag group aft~ te- activati% the project in 1990, was to mevaluate and finalixe the PDF plaat strudum ‘Ibis was esential for design of the foundation, an early item on the Project B&s&% Schedule for construction. IkingmurOintcndstruchue,thesteclhsdtobedebllsdMdordendarlyio the schedule also. The review of the PDF structure was mmpkted expediently and resulted in signiticant reductions of floor sppoe and stcd. The revised plaMi#Ig drawingr Of the Wuctmw for the PDF building and screening building elevation views are shown in Figunzs 5.8 thmugh 5.12. Figurer 5.13 thmugh 5.17 show the fmal floor plans for the PDF struchm drrsenino building.
MSHA requires that a ccal dryer bc sqxmuul from other coal handling frciliries by 100 feet or more or, if mclosed in a mmmon building, the dryer must bc segerati by walls that wilt prevent a d&g&on from entering other parts of the building. SpaM venting mquimneots also affect the dryer off-gas ductwork and cyclone inlet and outlet ductwork. Hue, explosim doors are required for pressure relief and a prmcss gas relief valve is -ired for both pressure mllcf and over-tcmperaturc of the dryer loop. ENCOAL chose to keep all PDF facilities in one building and thus zoned the building to meet the MSHA requirements. Zone 1 was unclassitlod and included the plant building up to tbo undarside of the @ flour. Zone 2 was the designation for the 6. through SA floors which contained the dryer. l%e headhouse at the top of the plant where coal enters was classified electrically and so became Zone 3, which had to bc pressmixed and scaled mechanically from both Zones 1 and 2. TIM previous figures show the floor layouts in each of these Zones.
5.2 MECHANICAL D&N
Pressure vessels, valves, piping, tanks and rotating equipment fall under the categoty of mechanical design. For the ENCOAL IWity, with its near atmospheric conditions, pressure was not a major problem. Other than utilities and fluid pumping systems, all pressurea in the LFC process arc measured In inches of water, both positive and negative. The main pmcess vcsscls were specified for two pounds of preyure and one pound vacuum, Consqucntly, none of the pmmrs wwls ware specified to be ASME Code stamped since Ms does not apply at thasn low prcssurcs. However, it was spccitied that all VCSWIS would be built in acconbmce with ASME code rfquiremeno. The exceptions to this standard were the utility boiler aad the liquid nitrogen storage equipment which required full AM6 Code certification.
It was recognivd fmm the outset that the PDF plant would go through a lot of start-up and shut- down cycles. Elevated temperatures dictated that pmvislons be made for expansion and contraction, so spring cans and expansion joints were inmrpomted into support for vessels, large diameter piping (ductwork) and cetin equipment. Piping larger than 30’ was isometrically detailed by Kellogg’s design group and furnished prefabricated to the fid em&n con@actor. All of this large diameter pipe and duchvmk was custom built fmm plate. Smaller d&me&r piping was specified to American Petroleum Institute (API) or American National Steel Institute
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(ANSI) standads. Piping smailcr than 3’ was furnished by the ereotioo coo&&or andwasfiad routed. All valves were supplied by Kellogg using their Vendor Quality Mmnganqt rpprorch when the design is dax joiutly with the veodor repre~@tives In Kebgg’r a@rering offus
Tire pmsenoa of high tempemtums and dusty, corrosive fluids in much of the gas and liquid pipingwasagivcn. Cubansteelwusd&ledu~hebucfforrllpiyinssyMms,wiOl refhctory lining systems for tempcmtums over 600% A protective coating kzwcoo the mfiactory and steel was applied. Over WOO*P, a dual mfmcmry liner consisting of formed pandrandthenpuMcdrwfIactorywuosed. txhewise,asinLlclayerofgunncdrefm#xymr specified, this layer being hardmed whem high dust loading was predictad for erosion pro&ct&a and modif& for acid r&stance where corrosion was also predicted.
Control of axmsim and erosion where refractory was not specified was also a concern. Verrclr and piping where acid condensation could take place wac lined with Haueloy C-22 or fabricam from Incoloy alloya. This included all of the dryer otT gas ductwork, cycloocs and blower housing. Hih comxion rates were not expected in other areas of the plant. Prior to the cyclones in the dtycr and pyrolyror loops, high dust loadings were expected, but there ullu were prokctcd by hardcncd refractory. Therefore the balance of the plant piping and vessels was simply given a 118’ comxion/crosion sllowance. Most of the time the actual wnll thickness was govcmed by st~ctural rcquimments, which made the wall thickness 3/8’ plus the corrosion allowance.
In many, industrial plants when availability is essential, the major quipment is spared by installation of rc&mdant parallel untts, each of which can handle full plant throughput. In the KNCOAL Project, being a demonstration plant. it was &&cd to spare only equipment in streams essential for process control. This minimised the capital cost and reduced the risks on the Projcct. As a result, only three critical pumps were spared with in-line, ready to run standby units. Based on the high reliability of the major quipment, this decision was not expected to have a significant impact on future plant availability.
All rotating quipment was specified to comply with current MSHA standards for 8 hour noise exposure and to be gas tight. Not every manuhcturer was able to meet the noise standard, but collcctivdy, the PDF building was held within acceptable limits. Even thwgh gas tight quipmcnt was spcclficd, an ambient air monitoring system was added to the PDF building to detect SO,. Hr!S, CH, and CO. The monitoring system was interlocked with the buildieg ventilation system and a plant evacuation alarm.
5.3 IKECTRICAL AND INSTRUMRNPATION DESIGN
Classification of the various plant facilities for the electrical design was one of the thirst engineering activities. Review of the National Rlcctrical Code (NRC) and MSHA regulations rcsultcd in the following area classifications:
Ciass 1, Division I, Group D and F: PDF building h&house, enclosed area under coal and PDF silos enclosed trenches
28
Class 2, Division 2. Group D and R Screening building; within 10 feet of conveyors, silo openings and trench cova% u- Itmhder of PDF building; remote buildings; cl- rooms
Thcsc classifications along with the rot&$ of the PDF buttding as de&bcd in Section 5.1 for prcssurc contahtrnent of the coat dryer, wuc review& with the MSHA Division of&c in Denver to get their input and coocunume. Pollowhtg these discussioos, the clas&ications wmo dissmninatcd to all design gnntps. Also issued wuo the 4160 volt and 480 volt one-line diagrams (Pigures 5.18 - 5.21) for all of the demonstmtkm facilities based 011 the equipment listed in the proass rclasc. Spam conduit, witing, switchgear locathnts, and junction box capacity were built htto the design to allow for futum additions and del&oru
AlroePrlyinthederiyphue,stududsmrckflnrdfwthemaon,nvitchgar,~~ frqucncydrivaandlhccwtrolsyo~n. Allmotomgreatcrthan5~wacfur&had byKelloUnthatbrnquipnrartMndors.mdwsrsspscificdDDkmiUMdchemialdutyMd energy emfht with a sc!lvic? hctor of 1.15. Switchgear was specified to IWet MSHA’r requimmmt for bypsming and testing at line on a monthly basis. &Iii state v&able ficqumcy drives wctu spccificd when required with locabrcmotc controt and ptogrammable ramping. For the control system, it was decided to use an Allen Bradley Ptogrammable Logic Cantroller (PLC) based system with the Control View operator intcrfacc mthcr than a m&t fiamc based distribotivc control system. This decision saved a considerable amount of moocy in hardwam and programming time and did not sacrifice anything in quality, flexibility or dam gathcrlng capebility.
F&g a first-of-its-kind demonstration plaot, a lot of axtm insttumcnmtion and sample stations were included in the tbcilities design, Gnc of the key clemcnts of the LFC Technology as developed by SGI is closed loop control and optimisation of the plant opemtion via sophistimucd computer programs. Called Level 0, this ultimate cootrol system requires r&able, accurate information from field instruments. Smtc of the art sensors for prcssuro, temperature, flow rates, density. pH and level were uscd throughout the plant. Two meas of concern were gas flow mcnsurcmcnt in the dirty, hot, corrosive process gas streams and the rcliible detection of critical kvcls. Hot wire anemomctm wcra select& for the seven!. gas flow applicatioos. Mechanical level detectors wcrc installed oo the dryer and pymlyzer outlets and nuclcnr dcvlces were spccifnd for all other critical level mcasummcnt appliions. Rod ccnl oomposiUoo and prodoct qualities arc also rcqtuircd by the Level 0 control system. The only proven inrhumcnt that could provide the instantaneous analysts n&cd for closed toop control was tha GAMMA-METRICS nuclur coat ~atyaer. Two of thcsc armlyr.crs wuc htstallcd in the plant, one on the raw coal inlet and one on the PDF outlet.
The Level 0 c~tfol system was dcsigncd to &de oo a mmom VAX computer and gather information throua a modem. It was a given that the demonstration plant would not start up using Level 0. Instead Level 0 would he put on line to “losm” by gathering data from the 132 tick! monitoring points, malting predictions for plant aperatIng paramctcrs and .%nnparing its predictions to the actual operating conditions. The Level 0 system would then lx calibmted during the tirst two years plant operation and eventually be put into on-line plant control service once it had dcmonstratcd reliability and accuracy.
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0;~ of the rmmmmendations of the HazOps study gtwup was to develop emagatcy abut-down [.:>!$D) proceduscz. 7% was dmse as pett of the initial ekcuicrl and instrumentuion dezign. sali& kmerly SD being pammount. the requirements for inzbument air capacity, nitrogen capacity and standby power were defumk@. A battery opmtcd uninlarrupbble power supply (UPS) was Insmlted to pmvide backup power to the contmL computers and cortain other &ctricaIly opcmted safety devices. In addition. for longer term outagq a standby generator was installed to maintain power to the UPS zyatem, nitrogen vaporizer, emergency lighting, standby glyco1 circulation pump and control room.
6.0 MAJOR EQUIPMENT FUNCTIONS AND DRSCRIPTXONS
‘Dse following sections discuss eech of the mr&r equipment items or gmups accurdii to function in the overaS process. For a more complete major equipment Rat, refer to Appendix A, Tabk A.1, which contains a cmss refesence of the equipment names and the number designation.
6.1 FEED COAL SYSTEhf
Coal is conveyed from the Buck&in Mime into a 3wO ton stomge silo (Figure 6.1). A variable speed vibrating feeder (Figure 6.2) loads coal automatiutly from the silo uoto a conveyor which continuously transfers the coal to a triple deck coal screen (Figure 6.3). 7he triple deck screen divides the feed coal into undersized (less than l/8‘). sized i(118 in. to 2 in.), and oversized @eater than 2 in.) materials. Undersired coal is returned to Triton via truck or conveyor. Coal greater than 2 in. is fed into a crusher (Figure 6.4) to teduce its sine. Outfall from the crusher is combined with the sized coal fmm the screen and is transferred to R 7 ton dryer coal feed hopper by an “S’ belt, a flexible wall. ribbed vertical lifting conveyor. A geoeral arrangement drawing for the coal handling equipment in the next three sections is shown in Figure 6.5.
6.2 COAL DKYER AND CYCLONE
The coal dryer (Figures 6.6 and 6.7) is a Salem Fumaro Company shallow bed rotary grate type dryer with a grate diameter of 39 ft. 9 in. The grate is pertonted for gas flow and has a circular opening in the center for discharging coal, Several typos of dryers were considered in the early stages of equipment selection: the choice was highly influenced by the d&se to minimize particle size degradation during coat hamlling. The coal enters tlm dryer at the oeter edge of the grate through the inlet chute. The distance between the diiharge of the inlet chute and the grate establishes the coal bed depth. As the grate rotntes, stationary rabbles (Figure 6.8). which act like plows. move the coal towud the center of the gmte. The cord then falls through the renter opening into a duct (soaking pit) which deposits the coal on the pyrolyse grate situated below the dryer.
34
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38
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igum 6.8 Dryer Rabbles Arrqemtnl
As the coal partlclcs move across the grate in a spiral path, they are in direct contact with a hot gas strentn that flows upward through the perforated rotating grate. The hot gas stream is a mixture of hot flae gas from the dryer combussor and recycled gas from the dryer. The inlet gas flow rate and temperature to the dryer are the two major control variablea which affect the drying pruccos.
Since the pefforattd grate of the dryer is rotating while the sheI of the dryer Is statlonaxy, a sand seal was installcd between the outer edge of the grate and the shell of the dryer to prevent the hot gas from bypassing the gtate through the clearance between the grate and shell. Furthermore, since the rotating structure of the grate extends outside the enclosure vesse1, water seals are installed between the external moving mnd stationary members to ccntain the gas within the dryer.
The hot gas that flows thmugh the perfonted grate removes the moisture fmm the coal through convective heat transfer. The go, flow rate thmugh the coal bed is not sufftckotly high to fluid& the coal. However, some coal flnen am entrained. The vapor stream leaving the dryer flows through a cyclone to remove most of the entrakd particulate% In the cyclona (figures 6.9 and 6.10), the dust-laden gas enters a cyliirlcal chamber tangentlally and kavu tbe vessel through a astral opening. The ccal fine particles tad to move toward the wall of tbe cyclone by the virtue of their in&a. Coal particles from the cyclone are collected into a hopper. The collected fines are dropped fmm the hopper into a screw conveyor/cooler (Figure 6.11) where they are co&d to ambient temperatute by indirect bcat-exchangc with cooling water. The cooled fines are then mixed with water and transfetred to the PDP cooler sump.
39
I. Figure 6.9 Dryer Cyclone
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L Figure 6.10 Typical Cycht Design
40
Figure 6.1 I coat Fine Screw ConveyorKzmler
A motor opxated v&e is located in the soaking pit which allows dried coal to drop from the dryer into the pyrolyaer. This valve can be closed to isolate one vessel from the other. When operating, a standing leg of solids provides a vapor seal between the two vessels.
6.3 COALPYROLYZRRANDCYCLONR
The pyrolyzer (Fiiure 6.12) is also aanufactured by Salem Furnace Company. Dried coal drops from the dryer into the pyrolyza through the scehmg pit. The design of the pyrolyzer is similar tn the dryer. lbc mechanisms by which coal is moved through the pyrolyaer and heated by a straon of hot gas are cssmtiahy the same as those described for the dryer in section 6.2. The grate is perforated for gas flow and has a diameter of 25 ft. 5 in. Solids are discharged from the pyrolyzer through a circular opening in the renter of the grate into a quench table situated below the pyroiyzer.
The gas kaviog the top of the pyrolyzer flows thmugh the pyrolyzer cyclone to remove entrained coal particulates. The pyrolyzer cyclone operates by the same principle as the dryer cyclone. The coal particulates that are r.a@ned by the cyclone am cotleeted into a surge bin where they are mixed with water to form a slurry. The slurry is pumped to a floor sump for treatment as described in section 9.2.
A motor operated valve is incated in the soaking pit which allows coal to drop from the pymlyzcr into the quench table. The valve can be closed to isolate one vessel fmm the other. A standing leg of solids provides the vapor seal between the pymlyzer and the quench table when this valve is opened.
41
6.4
Hot pyzolyzed coal prticles drop from the pymlyzer central discbarge chute onto the outer edge of the mtating deck of the Salem quench table (Figure 6.13). The rotating deck is lined with refractory and has a circular opening in the center for discharging solids. Ibis mtating deck is not perforated, thus beingdiffennt from those in the dryer and pyrolyzer. As the table rotates. stationary rabbles transfer the pyrolysed coal from the perimeter to a central outlet chute. As the pymtyzed coat particles move across tbe table in a serial path, they are quickly quenched by spraying water on them to stop the pymlysis reactkut. The stmm that is generated by quatching the solids is wnt to a condenser (Figure 6.14) where it is condensed by cold gQcoVwater solution. ‘The condensed water is recycled back to the quench table.
6.5 PDF CODLRR
lbe quenched pjrolyzed coal h dropped from the quench table discharge chute thmugh a rotary valve bno the PDF cooler where it is cooled to ambient temperature. The cooler (pigum 6. IS) is a rotating cylindrical vessel which measures 11 ft. in diamettr and 50 ft. in length and is manufactured by the Rennenberg Division of Hey1 and Patterson. A general ammgement drawing for this vessel is shown in Figure 6.16. The vessel is oriented horizontally with a slight incline angle. Internally, the vessel contains 120 cooling coils which run the length of the vessel. The coils are 3 l/2 in. in diameter with conling water flowing through them. Thus, the pymlyard coal is cooled indirectly in this vessel. The solids enter the end of the cooler, which has a slight vertical lift, tumble over the cooling tubes, and flow out the opposite end.
42
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6.6
The woled solids, now PDF, drop fmm the PDF cooler onto an 9” belt which is a flexible wall, ribbed vertical Wing conveyor and has the same design as the raal feed “S* Wt. The PDF is conveyed to a GAMMA-METRIC coal analyser (Figure 6.17) which measures its moistun, ash. carbon. hydrogen, nitrogen, sulfur and Rtu contents. After the PDF passes through the analyzer, it is dropped into the PDF storage silo. when the PDF stomge silo is to be emptied, a mass flow feeder transfers the PDF from the silo into a dust suppressant applicator in which a dust suppreersant known as MK is applied to the snrface of the PDF.
6.7 QUENCH TOWER
The quench tower (Figures 6.18 and 6.19) is a typical packed-bed column which condenser the organic6 in the off-gas from the pymlym cyclone by brtnging the gas into direct countercurrent fantact with a liquid (CDL) strum. A gutezal armngement drawing of the poach towa is shown in Figure 6.20. The vessel is 12.5 ft. in diameter and 80.5 ft. in height. Internal vapor and liquid reflux distributors are provided to aohiivs cross-sectionally uniform vapor and liquid flows. The column contains a bed of Oliti Orid packing which provides ample surfaw ark for vapodliquid contact. Cooled condensed organic liquid (CDL) is circulakd by a pump to the top of the column while the off-gas enters the column from the bottom, By direct cvntaet, bat is removed from the off-gas by the CDL and desirable organics condense in liqtdd form. The hot CDL is then pumped fmm the bottom of the column through a shell and tuba h&-exchanger where it is cooled by a 50/50 glycul water solution as described in Section 7.4. Most of the cooled CDL is recirculated to the top of the quench tower as reflux; a small portion is sent to storuge. l’be temperaune and flow rate of the reflux are controlled to give the desired exit temperature for the gas stream leaving the top of the tower,
44
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ELECTROSTATIC PRECIPITATORS
The gas stream leaving the quench tower may contain some CDL in the form of a fine mist. It was predicted tbat bctwcen 25 to 50% of the CDL condensed in the quench tower could be smaller than 2 microns drop size. In order to recover the mist as liquid, three l&go Cottrcll electrostatic prccipitatom (ESP) operating in parallel were instailed. Pigurc 6.21 shows a general arrangement of the ESP’s. Each vessel is 13.5 ft. in diameter. 24 ft. 4 in. in helgbt, and contains nearly 300 electrodes (Figure 6.22). In each tube is a wire eleotmde (Pigure 6.23); the liquid particles are charged by an electric tleld and move to the surface of the tabe where they are collcctcd. This is achieved by maintaining a hiih electtiA potential between tha clcctrodc and the tube Liquid collected in the tubes runs down the lube wall and is collected in the open bottom section of the ESP. Prom each of the 3 ESP’s, the liquid Sows by gravity into a collection line that transports it to the bottom of the quench tower where it combines with the rest of the CDL.
6.9 COAL DERIVED LIQUID (CDL) HANDLJNO SYSTJ5M
The net liquid product from the LPC! process is taken as a slip stream from the reflux being roturncd to the top of the quench tower. As the CDL flows to stomge (Plgure 6.24). it is anaiyzed for immiscible water content by a BS&W monitor. If the water content is grcatcr than 1 pcrccnt by volume, the CDL is considered to be off-specification (off-spec) and is automatically diverted to an off-spec CDL storage tank. Off-spec CDL can be pumped back to the quench tower for reprocessing. If the CDL meets sqrecitication, it flows into the CDL product storage tank.
CDL can be loaded to tank car or tank truck from the storage, tar& thmugh a CDL loading pump and meter (Figure 6.25).
47
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51
6.10 DRYER BLDWBR
Bccirculation of bo( gases in the dryer loop is pnsvidad by a large blowa (ngttre 6.26). Recycltd gas flows from the dryer cyclate to the suction of the btower. The gas it then pushed by the blower, mixed with the hot flue gas fium the dtyer comb&or, and moved into the dryer under tht gra?t to provide bent for the drying process. TJtt dryer blower is a bib-volume, low- head fan driven by a 1000 HP, 1200 RPM electric motor. The motor is eamected to the blower through a variable speed fluid-coupling. Qas flow demands M met by adjusting the settings on the variable speed coupling. The maximum bad difftrtntial that the blower will develop is about 23 in. of Hz0 pressure. The height of the blower shell ia 16 ft. and the suction and discharge ducts are 8 ft. in diameter.
6.11 PYROLYZBR BLOWER
A 600 HP blower moves the pyrolyxer off-gas from the ESP’t to the combustor5 and to recirculation in the pyrnlyzer loop. The shell of the pyrolyzer blower (Pigun 6.27) is 12 It, 3 in. in height and a 1780 RPM motor drives the blower. Cias flow control is achieved by adjusting an inlet damper located at the blower suction. The maximum differential head that the blower will develop is about 31 in. of HsO pressure. The suction and discharge ducts are 4 ft. in diameter.
52
1 Fi igurc 6.27 Pyro1yz.e~ Recirculation Blower
6.12 CONBUSTCJRS
The dryer and pyrolyzcr combustcrs (Pigun 6.28) arc gas fired heaters which supply the heat rquircd for drying and pyrolyzing the ccal. A general arrangement drawing typiul of both combustors is shown in Figurc 6.29 and Figure 6.30 shows the bttemals. Rccyclcd gas front the discharge of the pyrolyzer blower, which contains non-condensibk hydrccarbonr, is the pdmmy fuel for each combustor. Due to the low Btu value of the rncycicd gas (W-70 BtulSCF), natural gas is burned as supplemental fuct. Each cornbustor is quipped with a forced draft air blower (Figure 6.31) which supplies air for combnstion and takes suction from the atmosphem. Each blower is driven directly by a 100 BP motor.
The combustors contain a natural gas fbccl pilot burner for the ignition of the flame within the eomburtor. Each combnstor is quipped with natural gas burners which can dclivcr a maximum of 17 MM Btu pu hour. The primary fuel burners am ring typs whiti contab~ clusters of nozzles. The burner management system for each combustor is controlled by individual programmable logic control (PLC) systems. The PLC monitors a number of variables and controls the natural gas and air so that the on-gas temperames to the dryer and pyrolyzer arc maintained.
6.13 PURGE GAS TREATMEm
‘In order to meet envimnmcntal standards, the purge gas being discharged to the atmosphere by the LFC process must be treated. The off-gas from the process, containing mostly water va~or, nitrogen, carbon dioxide and small amounts of sulfur oxides, (Table 6.1) is vcnlcd to a derulfurization unit (Figure 6.32) which consists of a wet gas scrubber and a horizontal
53
Q+re 6.2R Combuslors
scrubber. The gas is treated with sodium carbonam solution which converts the sulfur oxides to sodiutir sulf&. In the wet gas scrubber, dual atomimtion nozzles disperse the sodium carbonate solution into tine particles with compressed air and spray it into the purge gas stream to reduce the entrained particulates and sulfur oxides, The horizontal scrubber further reduces sulfur oxides in the purge gas as it flows horixontaliy through spray curtains of sodium carbonate solution. The gas then passes through mist eliminators just prior to leaving the horiaomaj scrubber to capture any entrained treating solution in the form of fine mist. (Figure 6.33)
Table 6.1 Purge Gas Composition
CQ Nl H,O SO, NO= 0, Solids
5t3- ii.ro 46.74 37.93 0.50 0.02 0.41 0.21
==%F ii.01 46.60 38.64 0.02 0.02
The sgml treating solution is dischargwl to an evaporation pond (Pigum 6.34) where the sodium sulfite will oxidize into sodium sulfate. At the end of the Project life, the sodium sulfatc, dried by evaporation, is enolpsulated in a clay linti pod, covered with top soil and reclaimed.
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Air To Notual
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I Rgure 6.31 Combustion Air Blowers
Page 57 @hted
1
Figure 6.34 Temporary Evaporation Pond
6.14 DUST SCRUBBERS
When raw coal is conveyed from the feed coal silo, through the screening facilities, to the dryer feed hopper, coal dust is generated as the coal is loaded onto or discharged from a conveyor. In order lo control the emission of dust, two dust scrubbers (Figures 6.35 and 6.36). one at the bottom of the feed coal silo and the other at the screening building, were installaL The dust scrubbers are used to collect coal tines at various transfer points i.e., the discharge of coal from or onto a conveyor. The dust scrubber, with the aid of a blower, pulls a suction at each transfer point. An the dust laden air stream passes through the scrubber, dual atomisation nosxka disperse water into a fine mist with compressed air and spray it into the air stream. The air stream then flows through chevron sepmators to remove the coal dust and water, and the clean air is discharged to the atmosphere.
During startup and shutdown conditions, Ihens are times when the facilities are not operatin@ at design conditions, and dried, underpyrolysed coal (off-qrec PDF9 is produced. The transfer of off-spec PDF to the PDF storage silo can be dusty. TIrerefore, two addition& dust scrubbers were installed. They are used to collect coal fines at various transfer points where PDF is conveyed, e.g. from the PDF cooler to the PDF storage silo, and from the storage silo to conveyors.
58
L I Figure 6.36 Dust S~rubha at coal Feed silo
59
7.0 mILlTIE
7.1 STEAM SYSTEM
A package steam boiler from York Shipley is used to supply 150 psia steam at a design capacity of 10,tXNY lb per hr. The package includes a water softener, dcaer&u, cbetnical injeotien system, steam boiler, and a vendor supplied control package. The water softener is used te remove dissolved minerals from the feed wata to prevat fouling in the equipment. Tbs dcaerator removes dissolved oxygen from the water to prevent corrosion. Chemlcalr are injcoted into the feed water before it enters Ihe steam boiler to ensute clean water with no dissolwd oxygen is used. The steam boii bums natural gas as the source of beat to vaporira the feed water into s&em.
Stunt is used at various utility stations lo&ad in the PDF building. In the analyzer bouse where gas-chmmatographs are used to determine the composition of various process streams, steam is used to provide beat for sample lines. Stam is also used to maintain the glyc&vater system (de&bed in section 7.4) tempuature during plant startup and shutdown.
7.2 INSTRUMENT AND PLANT AIR
Compressed air demands in the facilities arc mat by two electrically driven air compnssors; at& delivers 750 SCFM of air at 12s psig discharge ptessure. The compressed air used to operate various pneumatic instruments and valves is dried to -409 dew point of water before its appliiion. Since the pneumatic instruments and valves are decmcd to be crucial to the operation of the facilities. miscellaneous plant air consumers will be. automatically shut off from air supply if the system pressure starts to fall, thus giving preference to instrumant air.
Compressed air is used at various utility stations lo&cd in the PDF building. Other major compressed air users are the dust scrubbers, the wet gas scrubber in the desulfurization unit, and the MK dust suppmssor. It is expected that one compressor will supply the total air ro$rements except when MK is being applied to the PDF.
7.3 COOLING WATER
Triton Coat Company has an 8-acre pond called S&nentation Pond No. 1. It is used for sdng suspended pat-tides from the mine water before discbarge. Coobng water circulation pumps take suction from this pond. The cooling water then flows through filters and into the cooling water system. The major users of cooling water are the PDF cooler, glycollwater trim cooler (described in section 7.4), dust scrub&q dryer fines screw cooler, and dryer blower fluid coupling. All the water which is used solely for indirect contact heat-exchange operations is retumcd back to the pond. The heat that is added to the pond by heal-exchange operations is small, and natural evaporation of water from the pond will maintain a satisfactory pond temperature. The largest heat loads on the system are the PDF cooler and the glycol/water trim coola.
60
1.4 CZYCOJJWATER CIRCULATING SYSTEM
The glytml/watcr system is a closal cimulatim heating and cooling system. During normal qeratim, procus heat is first absorbed in tbc system and then given up to brat consumers or hased IO the atmosphere and/or cooling water. During startup and shutdown situations, what process heat is not available, the system is heated with steam to maintain the naeswny user tcmpcraturc.
A c&d 50/50 glycoUwater solution is stored in a 150-barrel storage tank. A circulation pump or its spare takes suction from the storage tank and disc- parallel stmams through the fo~knving:
Fyrolyzer Quench Stam Comknser Qumch Oil (CDL) Coolers Glywliwattr !&am Heater
During normsl operation, glycol/water is usut to condense steam in the pyrolyxer quench steam condenser. The steam is generated in the quench table by quenching pyrotyxod coal with water. In the CDL cooler (Pigure 7. I), glycoWwatcr extracts heat from the CDL so that the CDL can be rccirculattd to the top of the quench tower as rcilux. During start-up and shutdown, the gIycol/water is heated by steam in the glycopwatcr steam heater. The three heat absorbing streams re]oin, forming a hot glycoYwater header to supply approximatc1y 1sSoF glycol/watur to heat consumers (i.e., tank heaters. host tracings, and MK applicathn hcatu).
The cool glycol/water streams returning from the heat consumers recombine into a header, and flow through a fm fan air/glycol heat exchanger (Figure 7.2) whii cools the glycollwatcr to 95°F by forced convective air, If the ambient tempetaturc is too high snd the glycollwater cannti be cooled to tbu design tcmpcrature by the fin fan cooler alone, the glycobwatcr will be cooled further by heat-exchange with cooling water in the glycollwater trim coder, whioh operates in series with the fin fan cooler. The glycollwatcr than rutums to the storage vessel. The temperature of g1ycoVwater to storage is controlled by a bypass acmss the two exchangers.
Since both of the glycol/watcr circulating pumps are driven by electric motors, in case of emergency, a small gear pump is used to supply glywllwater to critical heat tnced lines. The electric motor for the smaller pump is conncoted to the emergmcy electric power supply.
1.5 POTABLE WATER
Potable water originates from the Buckskin Mine’s water system and suppllcs the PDF area and administration bullding via an underground msin. In the PDF area, potable water services the emergency eyewash and safety showers, and is the feedwater for &cam generation. It is also the source of water for preparing the glycollwatcr solution in the storage tank,
61
I Figure 7.1 CDL Cooler
Xgure 7.2 Fin Fan Glycol Cooler
62
7.6 FIREWATER
Fiiater for the PDP area is supplied from the existhrg Tritort undetground firewater makt. The new extension from the T&on system sPRts into three btanches. One branch partially rings the unit area, supplying water to fin hydrants located outside the PDF structutu. The second branch supplies firewater to hose stations located on each level of the sereoning strueturu. The third branch supplies firewater to hors stations on each Inn! of the PDF building. ‘lbere am ten levels in the PDF building. Fach level contains, as a minimum, are firehose statioa. lbo water supply IO each of the lower five levuls contains a restriction orifice to prevent excessive flow from decreasing the available water to the upper five levels.
A firewater booster pump was instslkd to inomase the bead pmssuru of tba firuwatar system withii the PDF building. thus ensuring ample water is available to the upper levels. The pump t&es suction from the undergn3md fimwater main and dlseharges Uuough a vertical header supplying water to each level. The pump is not spared but does contain a full line sirs bypass. Normally, the bypass line is open and the pump is aligaud for automatic starting. The buRding fimvater prcssurc is maintained from the existing system thmugh the pump bypass. If tbe water pressure within the building decreases due to beavy demand, a pressure instrument wiR sense Ihe situation and automatically start the booster pump.
On the lowest level, the tirewater header extends approximately five feet outside tbe PDF building and terminates with a block valve and two fin hydrant type noaxles. The intent is to connect a tire truck (pumping iJpe) to the nozzles to supply the fimwatcr when the firewater booster pump is out of service for maintenance. The Are truck pump will take suction from the underground timwater main through a fire hydrant nozzle.
7.7 NlTROGEN
Liquid nitrogen is transported to the plant by truck and off-loaded into an 11,ooO gallon oryogenic slorage vessel. Pressure on the liquid nitmgen storage vessel is maintained at 100 psig. The liquid nitrogen is v+orized to supply gaseous nitrogen IO thr: faci!ities at 100 psig and 40°F. The vaporising coils are contained in a rtalic water/glycol mixture bath that is direct fired by a natural gas burner.
Nitrogen is distributed to utility (hose) stations in the PDF and rreening buildings. Additionatly. it is hard piped with Pressure regulators and trip valves to prevent vacuum conditions from occurring in the following vessels:
Coal Dryer Dryer Cyclone Pyrolyzer Pyrolyzer Cyclow Pyrolyzer Quench Chamber ESP’S
63
i H
In caw of a process upset wham the above equlprnent maybe sum to vacuum conditions, nitrogco will be introduced into those vessels to maintain a prnsot minimum internal pressure. In addition, before each startup, &ogen ls used to insrt the drying ud pyrolyxing loops to reduce the oxygen content. It is supplied to the combustors as purge gas to inert the combustor before it is light& It is also used as the purge gas for various insbuments. Moreover, the ESP vessels require nitrogen to continuslly purge and pressurise the electrical connection dome Chllt!W.
7.8 NATURAL GAS
Natural gas is the main source of fuel for all the building heating equipment in the facilities. It is supplied to tho unit area from Wostem Gas P mcwsors pipeline. Natural gas is used to fm the spaoz heaters, nitrogen vaporiser, feed coal silo heater, PDF silo heater, package stepm boiler, and both dryer and pyrolyaer combustors.
8.0 CONSTWJCTION
8.1 CONTRACTING METHODOLOGY
Construction of the ENCOAL LFC plant was donv: by Kellogg Construction Inc. (KCl) as part of the EPC contraot with The MW Kellogg Company. Due to the short time allowed by the original Construction Schedule shown in Figure 8.1, a fast hack approach was used, that is the field construction overlapped the engineering phase for all but the first two months. KCS, as the project manager, chose to implement the project by hiring subcontractors rather than use their own labor due to the remoteness of the location compared to their normal work ares, KC1 was abla to find an adequate number of qualltled local contractors to bid and perform the work. All work was done on a merit shop ‘basis.
Shortly after the ENCOAL Project was approved and went into design, Triton Coal Company, the site host started construction on a project to expand the Buckskin Mine coal handling facilities. A number of interferences between the two pmjozts resulted in some design changes, but for the most part, there wem advantage; to both projects being in construction at the same time, Having contractors available on site reduced mobilixation costs and being able to offer more work made contractors more competitive. In tho case of the earthwork and the concrete silos, ENCOAL being a sister company to Triton, was able to ‘tag on’ to existing competitively bid contmcts and start geld construction as soon as (he design work was done ln those areas. As a result, ENCOAL subcontracted directly for the earthwork and silos and KC1 managed the work in the field.
64
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0.2 CONTRACX PACKAGES
As dimtsscd above, KC1 clcctd to pufomt tba oonst~~tion pb by using subcontraotom for all field work. The result was 17 mrjor subcwtrect ‘paokagca’ for speoiafty work as out&d in Table 8.1. The advantages of this method were:
:i; improvud ability to do work in paraIM and save time e&wad bettct match of suboontmctor skills wbh the spccirlty work to be done and saved the mark-up that e general contmctor would obarge,
(3) allowed more smatl and small disadvantaged businesses to compete for tbe work, and
(4) coabled KCI to use more local conttactors.
Tbo disadvantages of the subcontractor approach were:
more effort was requited to coordinate the on-site work end there were mom interface points between subcontractors that had to be worked out.
Theadvantages far outweighed the disadvantages on the project and many qualified looal firms wcro sucwssfuUy employed.
8.3 MRTHWORK, SURVEYING AND TRSTfNG
The initial rough excavation for the PDF plant and screening building was done by Triton using a large mining shovel and trucks. Several thousand yards of material had to be moved and this was the most efficient and expedient method. Completed in Se:%mber, 1990, the work only took two days. For the fine grading at the plant site and overall site preparation, a contmct was awarded to the low bidder on the Triton expansion pmjeot. IMy surveying work was also done by exteuding one of Triton’s contracts since they were on she and had all the ground control points established. This initial work was.managed by ENCOAL and T&on prior to mobiliin of KC1 in the field.
By October, 1990, Kellogg had completed enough engineering to defme the scope of work for e total site preparation package, complete with drainage, roads, ponds, plant buildings and tank farms as described in Section 5.1. KC1 then mobilised at the plant site and develo@ an office for the construction team that would follow. They bid the earthwork, s!nveying and materials testing and awardcd new subcontracts for each. Site preparation hegaz i ;i earnest at this point.
As e matter of practice, all engineered backfill was tested for compaction and all st~ctural concrete was tested for proper mix qualities. Test cylinders were taken from each major concrete pour and tested for seven day and 28 day stnzngthr. Spot checking of welding was done for general piping and plate work. Natural gas piping was inspected by x-my techniques on 100% of the welds. A materials testing contractor performed all of these services.
Tabk 8.1 Subcontractors for ENCGAL wect
PACKAGE
Mechmlical Erection
Elccbical & Instr. Architectural Bldg.%
Abuve Gruund piping Farthwork Foundatiens
Concrete Silos
Surveying
Materials Testinn
Summit Construction
Hladky Construction AGE Construction
Hladky Constrnction Hoffman Inc.
Eaele Survevs
C.E. Kc MT. Undergreund Piping IllSUhtiOIl
Ceramic Lining
Rail Sidine
Larry’s Inc. Y 12 a69 Hladky Construction Y 6 245
Coors Inc. N 5~ 135 Midrest Railroad Y 9 127
The design for the demonstration facilities called fur Rtree days of raw coal stmage ahead of the PDF plant, two days of PDF storage after the plant and 12,000 tons of long term PDF storage for unit trains. To accomplish the latter, a swap was worked out with Triton to add 12,OMl tens of raw coal storage in tke new expansion facilities (a mere useful arrangement for them) and take ownership of two existing KQO ten storage silos that were much easier for BNCOAL to use. Included was the use of some existing conveyors. sampling systems, additionat storage silos and rail leading facilities. This saved ENCOAL a great deal of additional capital and construction work that would have been required to meet the needs for lung term PDF storage with its awn new silo.
8.4 STORAGE SILOS
Ho- Inc. was the socwssfu1 blddw on Triloll’s two plumed 12,om ton silos for their Egject, Confpluurtially, ENCOAL negotiated a cmtract with Hoffman for a third
~of~rllowumuug~byTritonMdwprmllundcnvaywhco KC1 moved to the site. The Pmject Mastu !kbedule tufktad that ENCOAL’s raw coal silo would have to be constructed very early in the job, because it would be very difficult if not impossible to build after T&on’s expansion conveyors we% inslallcd. The active til loop on one side and the conveyors on the other would pent access. Themfom, the design, specifxations, bii and award of this silo was eapcdital by Kellogg. Consttucdon of Ute 3000 ton feed coal silo beginning with the cni.~~~s and pile cap was started in Novembw, 1990 as a result of these efforts. The slipformcd, continuous camcrc& pour WpI completed in early February, 1991 during a fortunate break in the weather. Figures 8.2 and 8.3 show the slip form just prior to starting and the wmplelod silo mpcctively. Ibe silo internnls and mof were completed in April, 1991.
The remaining loo0 ton PDF product silo also ncaicd to bs completed fairly culy in the schedule to avoid conflict for access with the mechanical em&on contractor. Being very similar in design to the raw coal silo, the contract for the PDF silo was negotiated with the low bidder of all the other silos. Caissons and a pile cap were also ~uirai for this silo, but the depth was much less, being on the order of 20 feet. The PDF silo slip was compleud in May, 1991 and tho internals and roof in July, 1991. Both the raw coal and PDF silos unre equipped with a stainless steel hopper liner to improve material flowability.
8.5 PDF PLANT
The construction sequence for the PDF building began with the installation of a large spread footer type foundation with integral column supports for the buttding structure. This was followed by the underground and underfloor piping and foundations that mounted on the spread footer. Then the concrete frost walls, trenches and floor sections were pouted. Next, the main erection of the structural steel and enncurrent equipment installation was done. Delivery of several large pieces of equipment were critical to the erection sequence. The expediting schdtde shown in Figure 8.4 was devehqed to track these mqjor items and make appropriate a@ntments in the construction sequence as needed. A detailed construction scheduk was developed based on these expcotcd dellverks of major equipment as shown in Figure 8.5. This schedule had to be adjusted several times due to lete arrival of equipment. FinaUy. as the PDP building war topped out, installation of the steel cidlng commenced. The screening buiklhtg. off-site buildings and piping were done es+.mtiahy in parallel with the main plant erection. Electrical and instromentation work trailed ah mechanical/civil work and was completed last.
69
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8.5.1 Founclations
l3ax@nial wvcys on the sit0 showed lhat soil amditions wue poor near the surfac8, but that with slightly man exavation, a suitable beming zone amld be mdwd in the area of the PDF building. This was not true for the silos because of tJtc smatl diame&r and high loading, thus caissons and Pile caps wem requited. A spread footer for the PDF building had an additional advantage from a timing point of view; the foundation could be placed before winter weather arrived and it would take less enginering time to complete the design than for individual fdtions for ack piax of cquip~t, many of which were not even sebxtcd yet. Spccit%atiions and bid documcntr for the foundations package were preps& in Houston priar to KCI’s mob&a&r.. The bid was awarded and construction started in euly October, 1990.
A ground breaking ceremony was held during miw in the i&ill stages of foundation installation. By the ad of November, the largest monolithic pour in the state of Wyoming, a 3000 cubic yard base, was m&e (Fig- 8.68.9). By the end of 1990. the columns wem in ptaa and the spread fontings for both the PDF building and screening wcrc backfiIlcd with compactat material. Closely foIlowing the comph%n of the major plant foundations, a subcontrxt was awarded for tie con- and tank foundations remote to the plant anx. The same subxmtractnr was the successful bii and they continual to work through the winter as the w&her allowed. completing tha additional fbundalions by May, 1991.
Figure 8.6 PDF Building Excavation
I 1 Figure 8.8 PDF Building Foundation Pour
73
I Figure 8.9 PDF and Screening Bui!ding Foundations
8.5.2 Underground Piping, Conduit and Rquipment &mdations
Completion of the spread footer for the PDP bunding opened the way for the piping and equipment foundations that were located on top of it. Requiring different skills, these .damtraets were awarded separately. Moat of the undergmund piping was specified as high density polybutylene plastic. Underground conduit was smndard weight PVC covered with red dyed concre& outside of the plant area. ‘DIC natural gas piping was polyethylene coated steel and the flue gas system discharge line which was 304 stainless steel. The subcontract for underground piping included all of the buried piping and conduit in the PDFlrcrceniag building area, natural gas piping to the property line at the gas supplier’s metering station, flnwater system with valves and hydrants, rtpinless tine and the cooling water lines to and fmm the sedimentation pond. Work began ~1 soon as the walber allowed in Mach 1991 and was completed by July.
In parallel with the underground piping. P subcontract was awarded for the installstion of the concrete piers, foundations, trenches and floors in the PDF and scmcning buildings. This work also began right after the winter weather cleared in March, 1991 and conthmed through June. Ench individual concrete pier or foundation was excavated through the compactrd backfill to the spread footer and attached to pm-installed rebar or dowelled into the foundation concrete. Tho pier was then formed, poured and backtitkd. Figures 8.10 and 8.11 show the backfdled spread footer prior to starting piping and equipment foundations and Figure 8.12 ahown these subcontracts completed.
74
I l4gun 8.16 Backfilled PDF Building Foundatim
Undergmund Piping and Fountiations in Progress
75
,gura 8.12 Completed Equipment Foundations an Floor Slabs
8.5.3 Mechanical Erection
A subcontract for the mccbanical enction of the facilities was bii in February 1991 and awarded in April. It was plamtad ta mobilise the subcontractor in May. Howeva. about this time engineering delays and ensuing equipment ddivmy delays &ted ta catch up with the Project. Structural steel and the first of the mqior equipment, scheduled to start arriving in IHay had slipped by more than a month. The mechanical subcontmetor did mobilim by 0~: end of May, but slowly so they did not run out of available work. As a reference for the disc%asiocs that follow, Appendix A contains a complete floor by floor description of the plant and screening buildings.
By (he end of June, the Project worked thmugh the delay problems and mat&a: delivery was in full swing. The PDF cookr, so large that it had ta ba delivamd by &l, had arrived and was sat as soon as the foundations were ready (Figure 8.12). The quench column was delivered in mid June and was set in place straight ti-om the truck. Both of these pieces of equipment had to be set before work could begin on the structural steel.
76
The 5tcd fabricator did an ex~ient job of keeping abead of the cruction contractor afta they started receiving enginmring drawtogs from Kellogg. The erection plan called for asscrnblyofthePDFquencbtabk,pyrolycaanddryuoothegrmmdonebyonesnd lifting them into place as tbc structural sW was going up. The Other major equipment that had to bo set on elevated hors its the structure was going up wore the purge gas scrubbers, EsP’s, recycle blower, pyroiyrer cyclone, dryer cyclone and largo diameter prefabricated ductwork. Figure 8.13 shows the quemch column in place and the first of the structurat steel in pmgtuss. Jn the lower right corner of the picture. the quench table assembly is in progress. Figure 8.14 shows the quench table in place,
The etcction plau worked very wvcll and provided the fleaibility to dral MI *e delayed deliwry of some pieces of equipment. Both of the large pmcsrc gas blowers arrived more than a month late but posed no tual problem in the erection sequence. The horizontal scrubber and ESP’s arrived close to the required dates and wnre ret in July. Figuns 8.15 and 8.16 show the pmgress at this point. Placement of the stm&ral steel on the 4. floor openal the way for the installation of the pyrolyzr vessel. The assembled pymlyzer is shown on the gmund in Fym: 8.17 and in place in Figure 8.18. The roof of the pyrolyzer appears in the lower right comer of the picture. Erection of the PDF structure was at about 196 at this juncture where the floor uea reduced to less than half of the ground floor ares. Figure 8.18 also shows the installed combustors. motor control bullding and fines bin.
One of the longest delayed pieces of equipment was the pymlyrcr cyclone. Structural steel was temporarily omitted in the area just to the leg of the pymlyacr to accommodate installation of this large vessel when it finally arrived. Originally designed as a single unit, the manufacturer shipped the vessel in two pieces to save shop fabrication time and it hsd to be asrmblcd in place. In Figure 8.18, the lower half of the pyrolyzer cyclone appears at the bottom of the picture on the delivery truck. Figure 8.19 showv the complete cyclone installed in the structure, (Cat&r) This pmccdun delayed stool erection for two weeks.
‘llm 6” floor was dcsigncd to suppoct 41c dryer and is the bottom of zone 2, the specially designed dryer containment aone described in Section 5.1, This floor was covered witb checker plate instead of gntinz like the rcet of the floors in the plant. Figure 8.20 shows the slart of the structural stcki aud 6 floor decking above the pyrolyaer. The plastic cover around the combuston is for weather protection for the Mactory lining work in progress.
Like the pymlyzer, the dryer shell was a&mbkd on the gmund as a unit and lifted into place after all supporting structural steel was in place. ft did not fit together well and a lot of timming and grinding was necessary to assemble il. Portions of the both the dryer and pyrolyzcr grates and substructure were preassembled by the fabricators’ shop. These StNCtUItS were bolted in pllcc loosely before installation of the roof of each vessel. After completion of the vessel, the grate assembly was rotated and all bolts were torqucd and the nuts spot welded as required by the manufacturer. Figure 8.21 shows the completed dryer assembly and the inlet and outlet ductwork (120” OD).
Figure 8.14 PDF Quench Tablo and 3rd Floor In Pi&X
78
: II
The last large piece of equipment to arrive on site, two months behind schedule, was the dryer cyclone. Welded into thms large pieces oo the ground, mch piece had to be lift& inthroughthcopcnroofoftboplant. AsshownioF~8.22,stnmauralstecl installation continued as leog as possibk around the open M while waiting on delivery of the dryer oyclone. During this time, ~tws were reduced ud shifted to the screening building, raw coal ctmvcpr and product cuwqor% Tne dryer cyclone a&cd in Iato February 1992 and the final secticot of structural steel wae placed as shown in Fuure 8.23.
The girts and metal siding on the PDF structure began to k install& in November, 1991 at the lower lovelr of tho building. The slnglc layer, unlmulatal panels went up fairly slowly due to wind and weather problems. A number of the openings on the upper floors changed during the building erection, thus ra&ing improvising by the siding subcontractor which slowed progress. Work on the siding was well undamay in Figums 8.22 mxi 8.23.
After the dryer cyclone was set, the way was cl& for installation of the PDF S-Bell, GAMMA-METRICS snalyza and &uctuml steel on top of !he PDF silo. Figure 8.24 shows this work completed as well as the rest of the equipment, piping and ductwork in the top sections of the PDF building. On the south side of the building, the raw coal S- Belt was installed end tbe picture in Figure 8.25 was taken just beforr installation of the fiber&ss stack. Final completron of PDF structure occurred in March, 1492 as iiiu5tratui in the aerial view in Figure 8.26.
, Figure 8.17 Pymlyzer Assembly
80
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.
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9
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[email protected] 8.21 Dryer, Inlet Duct and Outlet Duct
82
. ”
83
.‘;;:.qy &r MY ./~ j_ll_-g _ ,““J ___ __I.. : ,Jsf- .-.>a+- y .y-J/ _, , & T’ * : . ” L .CA) y-y-- ,,r‘ - !Tf r
- 5:: ‘.C~ .*; .‘a ’ .-c
igure 8.25 In!
k&e 8.26 Aerial View of Compkted Plant (Center)
8.6 SCREENlNG BUILDING
Sqaratcd from the main PDF stn~3ure by 20 feet, the mw coal screening building contains a large dust cokector. a screen, crusher, 100 ton storage bin and loadout conveyor. This equipment was located remote from the plant due to el~trical classification, noise and tiration. A spread footer foundation was also used for this 90 foot high structure aed was installed under the same contract as the main plant. As mentioned above, whenever work stewed en the erection work on the PDF building, part of the conswetion crew moved to the assembly of the screening building.
Pint, the prefabricated, field erected stomge bin was asmmbled and welded together. Then the building was emoted around the bin, setting the quipment on eaoh floor on the way up. ‘Ibe design of this buitding was completed by tbc KCUENCGAL agieaerieg team in the field. Numerous misfits between the conveyors, nuxhaniad quipment and building structure had to be correoted. The cost and schedule impacts of these changes were minor, however, since the building is small. The siding contractor moved over to tbe scrcudng building a&r compktmg the PDF building ard completed installation of the triple wall insulated panels in Match. 1992.
A heating unit was installed on a small pad outside the building. Fiiure 8.27 shows ths mechanically complete screening building just before starting the siding. The completed screening building structure is shown in Figure 8.28.
85
I Figure 8.28 Completed Screening Building
86
8.7 ABOVE GROUND PIPfNff
~~yourd~cootrulcond~of5oiluns,glpol/maahat~liacsMdtbs CDL loadout rack. The piping was installed on pipe racks betnssn the PDF plant and the CDL tank fsnn (Figum 8.29). A large trench was includut where the plpbtg crossed a bat11 road tbr mine trucks. The work also included all of the plping inside the tank t%rm bchveca the off-spcc CDL tank and the 15,OW bar4 atorage tank, setting tlm pump, for CDL circulation and fismlshing and iwtalliry the CDL truck/train loadout platform (Figems 8.30 and 6.31). ‘fhie subconhact was bid and awarded in the fall of 1991 and mat of tbe work was complete by December. However, late delivery of the 8’ CDL loadout pwnp and up&ally the p&iv0 displacemmt meter ddaycd the final completion of the above gtumd piping pac@e until April 1992.
8.8 AR- BUILDINCi8
Four buildiigs remote !%om the main PDF plant and screening building area were required for tho ENCOAL Project. Two were pte-enginccmd metal buildings, the control mom and the main electrkat subsuttion. The other two were concmte block, namely the motor contml center (WC) and the cooling water pump house. lho four huildtngs were bid as a package under one subconttact snd awarded in June 1991. Priority was placed on the MCC! building to clear the way for the electrlal and instntmentation subcontractor, sinoe that is where the majority of the power and instrumentation wiring and rwitchgcar had to be located. Them were no major pmblemq with the MCC building and it was completed in August (Figum 8.32). llte next building in order of priority was the pump house, but it could not k stattcd until a permit modification for the existing sedimentation pond changes was received. Therefore the subcontractor moved on to the substation building next.
figum 8.29 Above Ground Piping
87
I Figure 6.30 Tank Faxm Piping
Flgure 8.31 CDL TmckRrain Loadout Rack
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i II
I Figun 8.32 MCC Building and 48OV Substatim
The substation builditt8 was completed in September, 1991. opening tha way for permanqt power to be supplied to the construction site. Up to this point, construetion power was supplied by a temporary tie-in to Trlton’a distribution system. ENCOAL’s control building was last on the priority list. Tlto foundations for the control building wan plmxd at the same time as the MCC building in July while awaiting delivery of materials. The oontrol building was framed in by the end of September and ENCOAL was able to move into its new offkos in )ate November (Figures 8.33 and 8.34). Permit appmval for construction of the pump house was finally received in September, 1991 and work was well undmway by the end Jf the month. Completion of the pump house, including the setting of the pumps and pdplng was completed by the end of November, 1991 (Figures 8.35 and 8.36).
8.9 ELECTRICAL AND INSTRUMENTATION
Bngineering and prqmement of the electrical and instrumentatlnn systems was the last home office work to be compbbd at Keilqg. as woold be expected. The subcontract for the electrical and instrumentation field instnBation was bid in April, 1991 and awarded by mid-June. The subcontractor, mobilised in July as soon as enough materUs wete on hand to keep the ctews efBeiently working. The instrumentation portton of the work was in turn subcontmcted to a spwialiit. Both of these subcontractera struggled for places to work at rimes throughout the project due to delays in quipment delivedes and slow pmgress on the mechanka) cmetion of the PDF plant equipment. These problems were minimised by contmlllng staff levels to matoh the amount of work areas available, Use of cable trays in the PDF plant instead of lndividuat conduit and the preplacement of cendult with the undergmund piping pacluge significantly improved the productivity of the electrical installation crews. Together, there two items resulted in a lower peak workforce for the elect&al and Instrumentation subcontract than originally pmjqted.
89
II
I Figure 8.35 Cooling Water Pump HOUO~
I I
I Figun 8.36
I Cooling Water Intake - Existing Triton ?ond
91
ovaail the eiectricaJ and instrumentatkm work wau fairly smoothly. Then were only minor &c&co probIetus with other trades as these subcontractors foEowed behind and undct the ~cmws. Omwwtantpmbiunwaswddspla~. Wddaxwcskingovwheadhadsobe rrmindedtoputdormflnb~andure~~~ppnvmt~onthelowerfloonfrom behrg burned. The same was true for welders on lho dectricd and it~strumaUation cmva wherr they were attaching conduit supports to the Xructum. Most of the motor coutmla and wkiug were in piacc by Jannary, 1992. Instatiadon of the inrtnuuentation wiring and equipmeat had to wait on completion of the piping, inciuding fiushii and test@. Tenuhutices took p&e from mid-January through April, 1992, which included hcoking up ail motors and cheddng for malian. The only subcontractor to ranain thmugh commissiontag, the duxrkai and instnnnentatimr crews worked dowdy with ENCOAL’S operations staff to get aE thciiities ready ta operate. Thoy aim hdped calibrate all instnment6. Pi completifm of the subcontract occurmd in May, 1992.
8.10 MISCELLANEOUS
Scvcral other subcontract activities were dovetailed into the construction effort over the course of the Project. These included the supply and field erection of the two CDL storage tanks (l- 2100 bbl. and l-iS,aoO bbl. shown in Figure 8.37) which was done on a turnkey b&s, Insulation of the piping and pumps was part of the above ground piping subcontract. Epoxy Uning for the CDL storage tanks and ceramic lining of the pyrolyrr cyciono were also done as scparate subwntracts. As opposed IO the insulation co&actor, where there was a lot of interface with the other trades with the scaffolding, tho latter two subcontm .- wem all intcmrl and posed no problems. A railroad siding for up to 10 tank ears was cons1 daspartofthe Project and it was done by a lccai subcontractor acceptable to the Burlingh r-them Railroad (Figure 8.38). This work was done during the dry summer months of 199 ~,. was compieted on August 15. Other small misceihumous work that came up during the ( of tho Project was handled by extending the scope of vork of existing subcontractors usir sted unk pricea.
Although delays In the preferred construction schedule did occur, tk .ait project was completed two months before the baseline schedule submitted to DOE, Including commissioning and start-up. Figure 8.39 shows the percent compiett. .rus time for the originat planned constructtan period, as revised during the construction t z!y and the earued progress (actual). Figure 8.40 shows theactual manpower requirements vt ‘5 the revimd plan. The actual Phase I (Design) and Phase II (Constmcttco and Start-Up) costa of $S1,272,800 were right on budget.
92
I I Figurc 8.37 CDL Storage Tanks Under Construction
. .~. .-.-L.~L- _., . ,. ,
Figure 8.38 Rail Siding Under Construction
93
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94
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91 ENVIRONMENTAL CONCERNS
During design, a high priority was placed on the minimizaiion of waste generation. Therefore, no significant environmental impacts or consequences are e.vIxcted tIma tho Rojrrst. AlI necusary permits for the construction of the facility were secured during the design phase of the Project. The design criteria for the demonstration plant met the Wyoming Depattmcnt of Enviromnentsl Qnality’s Ilest Availabie TechaoIogy criteria in mrery aspect. The foRowing sections briefly hiihlight : e design measures taken in the affec&d mvIrrmmentaI disciplhms aad their anticipated impacts.
9.1 AIR POLUITANTS
During normal opemtkm, my purge gas that is dossed to the atmosphere must pass tbrougk the destdfubtion unit, and any purge gas that is prmhxed in the pyrolyzer loop mm be sent to the &sulfuhation unit only after it has been incinuatal in the dryer combustor. Therefore, air polhnants emitted horn the PDF building stack consist only of minor amounts of NO., SO,, CO, hydrocarbons and particulates. Emissions for each pollutant are below the 1BO ton per year Ievel for named (fuel conversion) sources. Rigorous parmitting and monltoting rsquimments were thus avoided. This was achieved through careful sekction of appropriate @b&on eoatroI technologies and process control equipment.
NO,, CO, and hydrocarbons emissions are minimized by timrmal decomposition in the dryer combustor. SOi and particulates emissions from the process are controlled by the purge gas treatment described in Section 6.13. In addition, particulates emissions from the crushing/screening building, raw coai storage silo, and PDF storage silo am controlled by wet scrubbers. The effrciencics of these scrubbers are over 99%.
9.2 WATER EFFLUENTS
The process is designed to operate such that no water will be condenmd during normal operation, thus eliminating the generation of wastowater contaminated by hydrocamons. All liquid effluents generated from plant upsets, such as off-specification CDL or intermediite prcducts, can be recycled back to the facilities and upgraded. Internal recycling of process sod clean-out water occurs through collection of such water in concrete floor containment trenches and vessels. This water, along with the pyrolyzer quench condensed water and other incidental streams (i.e., leaks from equipment seals), am collected for process usage
Washdown water from the solids handling portico of the facilities, (i.e., from the raw coal storage silo, screening building, and solids handling systems in the PDF building), and the discharge from the wet scrubbers are collected in floor sump, located at varkms areas. It is then pumped to a collection sump in the screening building. This collection sump allows the eftIuent to pass through a bank of hydrocyclones for separation of solios from the liquid. ‘Ilm liquid portion is pumped to the Buckskin Mine Wastewater Reservoir No. 1 for treatment and settling prior to discharge to the environment. The separated Enes are added to the fmes storage bin in the screening building which is used to store the undersized material from the triple-deck vibrating screen. The fines are then returned to the Buckskin Mine product via truck or conveyor. When the hydrocyclones are out of service, all soliis report to the settling pond.
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The sodium sulfite effluent getwrated by the purge gas treatment system (demribed in S&ion 6.13) is pumped to a tempnrary pmcipitate stomge ramrvotr. The rrr+%voir provides sufkiatt surfsco area to promote natural evaporation of water and oxidation of sodium ail& to sodium sulfale. This pmcipiatt. in lhe form of a shmy, is nonhax&ousandnontoxic. Thetempany storage of the pro5pitate is codned within a clay liner until a pemunent disposat facility is designed, permitted and constructed.
In the wnwpmal design, tbe pemument reservoir will be doubln lined with 8 IenR detectionkadbreak system. The liners will be composed of a primary synthctie membrane liner and a secondary amended clay liner mpnmted by a geonet drainage layer. The reservoir will bo desigd to chattnet any leakage cnkring the drainage layer to sumps for return to the roscrvoir. This design allows both continual monitoring of the synthetic liner integrity and, in the event of a lull in the synthetic linm, maintenance of a minimum driving head 00 the sewndary clay Iin+ themby effectively pteventing leakage through the liner system.
As discussed in Sec.&n 7.3, cooling water is cbtained fmm Buckskin Mine Sedimenk&m Reservoir No. 1 for hulked coolmg applkatimts. make-up water, and washdown. The existing Triton water allocation rights encompass the net consumption that may be needal to supplement the cooling/makeup water strum. It is anticipated that the cooling warn return to the resavoir will increase the reservoir temperatum by 8 KI 10°F. No environmental effects arc predicted under the National pollutant Discharge Elimination System (NPDES).
9.3 SOLID/HAZARDOUS WASTE GENERATION
No solid haxardous waste is expected to be generated from the prccess as explained in previous sections. Sodium sulfite solution will be sent to the temporary precipitate storage reservoir. If complete evaporation of water from the reservoir is assumed, a nonhazardous solid waste of coal tin&odium sulfate mixture is obtained. Current design philosophy plans for the eventual on-sits disposal of this material. The l/8” x 0” rejected coal collected in the screening building is returned to the Buckskin Mine as a salable product, thus avoiding the generation of additional solid waste.
10.0 SAFETY PRAcrIcEs
Safety is integmkc: into the design and operation of ihe facilities. The on-site safety program, established at the i%tckskin Mine, was carried over to this Project. Spa% ENCOAL safety proccduns were kIeveloped which speciQ actions required during operation end maintenance of the facilities to yotect workers’ h&h and safety. During construction, the safety program was meapgcd by KCi.~ There were a numhcr of elements to their highly successful program that M discussed in more de&! below, ::~
10.1 INDWrRIAL HYGIENE
Evcyeffortwasmndedmingdmigntoreducewmkerexpmums lopolendsl- mate&Is or conditions. This was achieved thtough exghmerlng contmk. MonksrIng wlIl aId in evaluabng the effectiveness of the enghmuing controls. The monitnring program wiR in&de persomd nunWrIng of workers potentially exposed to a haxmd as well as aren and/or source monltoting. Remote air conkminant tnonilon will detect unsafe levels of CO, HsS, So, and CH,. These monitors trigger audio signals to warn of air conkminank. They am part of the controlsyptans~initiatcand~~conditiahc~~~~to~~ respom pmedures. A physlcnl inspection and gas dekcthm evaWion of the plant is conduwdukutwicedailyloenuvttbrtarruuenfefor~.
10.2 PHYSICAL HAZARDS
The primary physical hnxmds associakd with the project are noise, extreme temperatures, and combustible materkls. Design efforts wem made to select equipment that genetnte low sound IntaulUes. Noise monitoring and surveys were conducted during skrtup to identify areas with noise levels which exceed the MSHA time weighted avemge ilmik. A beating consen&on program has been exkblished for these anm.9.
Heat stress will be evaluated during plant operations to determine if design messums (liners, coatings, insulation and ventilation) provide rufflcient protection for the workers. Cold stress may be. mvimnmenklly induced in exeess of design consldemtlonr (siding, heating and ventRation systems). Additional opemtionai measures will be determined pending the resulk of thwe assesunenk.
Combustible matedals are inherent in any coal handling and processing fpcility. The major haxsrd is the aecumtdatlon of coal dust. Regular clean-up procedures must be pmcticed to prevent the accumulation of coal dust. Daily itkpectlons are required throughout the facilities to ensum that no combustible matedal accumulates.
10.3 CONSTRUCDON SAFETY PRACIlCRS
The safety program admitistered by KCI during construction was very successful as dncumented by Figure 10.1 which shows the lost time and reportable incident rate for the const~ctlon phase of the Project. Basic conskuctlon safety pm&es were developed Jointly by ENCOAL and KU incorporating MSHA tequiremenk and T&on’s established pm&es. This effort resulted in a document that beeanie part of all subcontmctor’s tezms and conditions. In addition to the conunctunI requiresoak, a number of mfe~y enhancement programs were institutionalised by KCI. Obese programs were a balanced combination of recognition/awsrds and posltlve, klr eoforcement of all safety practices as follows;
(1) Enforcement Univermliy appiled policies and rules together with appropriate discipline when needed.
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0 “STOP’
(4) Meetings
(5) caw Management
AsrctyudptOdUCtiVity arhrncement pmgranl that irlvolvQ au site pumnncl and thdr fiuniliw. At ENCOAL, s8fcty a- andinvolvematwasacbievedtbrough~s&tycoxnmittecmadcup of rcprc.xnt#iv~ of each subcontractor, KC1 and ENCGAL. A safety suggation program, s&y ctew of the month, employee of the month, saf&y poster contc4ts for childtwt, &mily site toun, picnics, udlcatone. afcbratlons and an awatds progmttt wem all uscdtoin-sufdya- Pmiodic aw8rds ulu wcm given included dinncxs for the employee and thdr spouse, caps, Jackets,swcUshbtsaodhellbockla. Amonthlysitencwsletter wa.sva.s~mbCsh&d with pictums ad slorks hiihlighting safety
SafUyTminingandObscrvationPmgtatnor@allydcvclopedby the Dupont Company. Tltroc series of classes were conducted dudng the construction period.
Dally ‘tuolhox” safety meetings wwc held by each subcontmctor and attended frequantly by KWJ3NCOAL. A weekly safaty committee meeting with minutes and action items was held and attendance was tequired by representatives of each subcontractor.
When an incident did occur, KC1 worked with the subcontmctors and local health providers to Insure the employee was prop&y treated, but that no tnmemwy prescriptions or tteatmcnts wcm directed that would hxrcasc the time away from work or &Me the level of an incident to a lost time. W doctors visited the site to discuss working conditions. MSHA tegulations and safety practices so they would be in a better position to judge an employees ability to perform their work safely.
It is belii that all of these programs contributed to the excellent safety achievements on the Project. Severa of these programs were adopted by subcontractors and ENCGAL for on going US
11.0 CONCLUSION5
The process engineering, detailed design and construction have been completed for the loo0 ton/day ENCOAL Mi Coal Gasification Project. The plant has processed subbiluminour Powder River Basla low&fur coal and produced PDF and CDL. PDF is a premium solii fuel with good burning cbamcteristics and low sulfur content. CDL has properties similar to a low- sulfur heavy industrial fuel oil.
The design of the demnnstmtion plant is based upon pilot plant studies which provided opuathtg dxtaand properties of products. Mechanical equipment selection resulted from many discussions with equipment vendors, as well as fmm the knowledge and expcriencc of members of the design team.
loo
The major design accompllshnmnts for the m IIC:
(1) dryioscazla\rrotur~byb~~~ittintodirrd~~withhotps. (2) pyrdydsofdrkdcollonrrourypnbPbybrinOingit~~~Mwilhhot
(3) %ing of pyrolysed coal by dimct water quenching and indirect heat- cxchangc with cxoling waler.
(4) condm14on of high Mling hydmdont from I gassow awn by direct vapor/liquid contact in a pa&d-bed column without condensation of water.
(S) treatment of a purge gas slrcau\ before its nlcue t&the 8tnmpMc.
Suftlciatt operating flexibility is built in& the plrnt to gumit extsmsivc cvahution of the m&r process wuiahh. Environmental -s and safety practices were given a vuy high priority in design considuada~.
Caostruction of the plant was accomplished with few problems other than minor equipment delivery delays. 7he total construction from s&rt to finish w less thus 18 months due to the successful fast-track approach and the work was done within budget. An exemplary snfety record was a&II.
It is believed that this prcccss npmsents acccptahlc technology and markoting risks. Commercial plants should p&do attractive investments. Both products ~JU aWonmcntally superior, and are viable fuels to help utilities meet the Clean Air Act Amendmartt of 1990.
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Sill&d goneral civil designs for the ENCOAL facilities are shown in Pigum A. 1 to Figure A.M. Fimm A.1 describes the general layout Of the facilities. The ditncttsions of mch stntcturc &d its nlative position tiappmxiniatcd. The control room for the facilities is shown on Figutw A.2 and A.3. Figures A.4 to A.13 shmv tbc PDF sttwtum and its simplikd floor plans. 7% relative dimension and p&ion of each pkcc of rpuiptwat M appmximatad. Piurea A.14 and A.15 doscribe tho scrwdng building. The quipmmt numbers shown on Figute A.6 to Fiium A.14 aro cross refarncul to their gaoml dcmigtions in l’bblc A.1.
igurc A. I ENCOAL Facilities Layout
A-l
I
Tgore A. 3 Interior of the Control Room
A-2
c
ruv suucture Loorrng Southwest
igure A.5 ENCOAL Facilities Looking Northcad
A-3
T k c
E4 t-7-+7-
-
7-b ----r
z c
A4
1- k -
A-S
.
A-6
A-7
H4
A-8
I +-I
A-9
q
f h I
A-11
.
L: l3gwe A.14 Screening Building
A-12
A-13
Tab A.1
Equipmenl I Dcxcrlpllon
101-F 101-J 101-v
101-w 102-v lob-V 105-P IDS-J 105-v 106-c 107-v 109-V
120-v 2001-c 2w1-u
2002~UL 2aos-c 2ocl5-J
ZOlWA
2006-F 2006-J 2007-J
2007-JA 2owI
201~Cl/C2 201-E
Fine Slurry Mixing Tank Dryer Recirculation Blower Coal Dryer
Diyer-MP= Dryer cyclone ~pytolyccr ’ Seal Water Surge Tank Scat Water Circulatiun Pump
PYdYW cyclone Pyrolyrer Quend~ Steam Condenser PDF Cooler Dryer Fiic Screw ConveyorKoolar Pyrolyzer Quench Chamber StcamlGlycol Heat Exchanger Stciun Boilsr Steam Boiler Deacrator Glycol/Water Trim Cooler Air Compressor Air Compressor Oity Water !&rage Tank
Oily Water Pump Olycol Circulation Pump GIycol Circulation Pump Cooling Water Boo&r Pump CDL CMlU
Quench Tower CDL Circulation Pump
A-14
Equipmmlt I Description 2014A CDL Circulatioo Pump 201-VA El~tatic Prcoipitator 201-VB Blanro~ntlc Preoipitator 201-VC Elcctrosntic Precipitator
203-J wash oil ciroulatian Pump 2101-J 2101-v 2102-v 2103-v 2104-F 2106-v 2 108-J 2108-V
Firewater Boostor Pump Triple Deck Coal Screen Caal Feed Conveyor coal CNsbu Scrcenin~ Building Dw’ SCNbbCf
Feed Cc& “S Belt Conveyor Screening Building Dust Scrubber Blower PDF “S’ Belt COnveyOr Coal Fine Collection Bin X16 Conveyor to T&on Facilities Vibrating Feed Under 2116-V Dryer Combustor Pyrolyzcr Recirculation Bloke Pyrolyzer Combustor Pyrcdyzer Combustion Air Blower Dryer Combustion Air Blower Horizontal 8crubber Scrubber Surge Tank Sodium Caknatc Circulation Pump Wet Gas Scrubber Sodium Carbonate Makeup Pump
2116-v 2117-V 2119.V 301-E 301-J 302-B 302-J 303-J 501-E 501-F 5014 s03-F 503-J --
A-15
Appendices B, C. D. and E Omitted
