SECTION 6.0
METHANOLSYNTHESISAND DISTILLATION
(Areas 213, 214, 219)
DESIGN BASIS
6.1
6.1.I
6.1.2
Methanol synthesis w i l l be by the ICI low pressure process.
Three trains of equal capacity w i l l be provided for converting the upgraded synthesis gas to methanol.
6.1.3
6.1.4
Operating pressure wi~l be at lO0 atmospheres.
Purge and flash gas w i l l be collected and sent to a reformer
for converting CH4 to H2 and CO which w i l l
be returned to
the converter.
6.1.5
Each of the three d i s t i l l a t i o n columns w i l l
be designed to
produce 2,500 stpd of fuel grade methanol.
6.1.6
Bottoms water w i l l be directed to the wastewater treatment
area for cleanup prior to discharge.
6.2
PROCESS DESCRIPTION
6.2.1
Methanol Synthesis {Area 213~ Dwg. 5530-213-Y-001)
The synthesis gas charged to the methanol converter is composed of makeup gas, reformed gas, and recycled loop gas. A
fraction of the synthesis gas is preheated to reaction temperature and enters the top of the converter as feed gas.
The following overall reactions take place over the copper
based methanol synthesis catalyst.
0815R
6/1
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CO + 2H2 ~-~
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CH30H
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CO2 + H 2 ~ C O
+ H20
The overall reaction from CO, CO2 and H2 to methanol is
exothermic. The remaining synthesis gas is preheated (to a
/../...
temperature substantially below reaction temperature) and is
injected into the converter at appropriate points along the
length of the converter. This "warm shot" gas is used to
quench the reacting gas passing down through the catalyst
beds. It moderates the reacting gas temperature and subsequently reacts to form methanol as it passes over the catalyst bed below.
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The converter effluent gas is cooled by heat exchange in the
warm shell interchanger, in the saturator water heater and in
.,...
the d i s t i l l a t i o n column gas reboiler,
The remaining heat is
removed in the cold shell tnterchanger. The a i r cooled crude
methanol condenser removes waste heat from the e x i t gas and
the Condensate (crude methanol) is knocked out in the methanol separator. A fraction of the gas from ti~e separator is
., ! ; " 14.
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purged to maintain the proper inerts level in the loop. This
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purge is used as part of the reformer feed and fuel.
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The
remaining gas is recycled through the circulator compressor
and the Interchangers back to the converter. The makeup gas
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addition is at the suction of the circulator compressor.
Crude methanol is flashed at a pressure above atmospheric to
remove some of the gases ph?sically dissolved at the loop
pressure. The crude methanol then passes under i t s own pressure to the crude methanol tank.
The flashed gases are sent to the rsformer as part of the
feed.
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0815R
612
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The methanol converter is a pressure vessel of stngle wall
design constructed of low alloy steel whtch holds a single
bed of catalyst. Temperature control is effected by injecttng "warmshot" gas at appropriate levels directly into the
catalyst bed using specially developed distributors called
L
lozenges.
The lozenges provide excellent gas mixing while
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a11owlng free flow of catalyst between them, thus allowing
raptd catalyst charging and discharging. Catalyst chanqeout
times of less than 36 hours from hot shutdown to start of
reduction of new catal3st are consi~tantly achieved.
The synthesis loop also contains a steam heated start-up
heater which serves to heat the cl~culating gases at start-up
and for catalyst reduction.
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6.2.2
Reforming (Area 219,/)rawings 5530-219-Y-001~ Y-O02)
The purge gases prodLiced by synthesis and d i s t i l l a t i o n
are
steam reformed to supplement the makeup gas required from
gastfters as feed to the synthesls loops. In practice, not
all of the purge gases can be fed to the reformer and returned to the methanol synthesis loops because the synthesis gas
also contains nitrogen which would build up i f some purge
were not maintained. Thus 75% of loop purge and all of loop
flash and d i s t i l l a t i o n light ends are fed to the reformer as
feed and 25% of loop purge is used as fuel to the reformer
which is supplemented by No. 2 fuel oi1.
Purge gas feedstock
is supplied at IO0=F and 350 psig. The feedstock is mix~:d
with process steam and heated to 900°F in the mixed feed preheater.
Preheated mixed feed is distributed equally to tubes packed
with natural gas reforming catalyst.
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0815R
6/3
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The reforming furnace is of "modular" design which combines
economical s t r u c t u r a l costs with s i m p l i c i t y of design. Heat
of reaction is provided by downfired burners, situated in the
roof of the furnace.
The burners are designed f o r f i r i n g
C.
purge gas and No. 2 fuel o i l .
Steam and purge gases enter the reforming tube centrally
through a top blind flange, pass through a 35 foot bed of reforming catalyst reacting to form reformed gas which leaves
through the outlet pigtail.
In the event of accidental tube f a i l u r e , i t is possible to
isolate individual tubes by a hydraulic nipping device which
pinches shut the " p i g t a i l "
connections at i n l e t and o u t l e t .
This operation may be carried out with the furnace on-line.
The reforming
reaction
is
basically
the
reaction
between
hydrocarbon and steam to produce carbon monoxide and hydrogen, The prusence of excess steam promotes the s h i f t reaction which w i l l a l t e r the f i n a l equilibrium composition of
the reformed gas. Typical equations representing the overall
~eactions are given below:
Reforming Reaction
CH4 + H20_eF__.~_C0 * 3H~
S h i f t Conversion Reaction
CO + H20
~
CO2 + H2
Heat is recovered from hot reformed gas by generation of
steam in the reformed gas boi]er, preheating the mixed feed
and boiler feedwater heating in the b o i l e r feedwater heater.
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;.
0815R
6/4
Final cooling of the reformed gas to IO0°F is done in the air
cooled reformed gas cooler.
Generation of steam at the 1500 psig level has been selected
so as ~ be compatible with plant wide steam generating
system.
Steam generation is achieved by heat recovery from reformed
gas and radiant box flue gas, The steam generation boilers
and the superheater utilizes a common steam drum and, for
r e l i a b i l i t y o natural boller feedwater circulation.
The flue gas from the furnace is also used to produce superheated steam, and to preheat combustion a i r .
6.2.3
D i s t i l l a t i o n (Area 214, Dwg. 5530-214-Y-001~
One of the major advantages of the ICI low pressure methanol
process is the excellent s e l e c t i v i t y of the converter catalyst and the consequent low level of organic impurities. A
simple d i s t i l l a t i o n system can thus achieve high efficiency
without requiring high rebotl heat loads. A single column
d i s t i l l a t i o n system is therefore provided. A part of the reboil heat is provided by the effluent gases from the methanol
converter and effluent gases from the hydrolysis unit and the
rest ls provided by 50 psig saturated stets,
The crude methanol is pumped from the crude methat,ol tank to
the d i s t i l l a t i o n system and is heated with the d i s t i l l a t i o n
column overheads.
To prevent corrosion, a premixed aqueous
solution of 1% sodium hydroxide is metered into the crude
feed at a rate sufficient to neutralize any organic acids
present. The heated liquid is then fed to the d i s t i l l a t i o n
column.
0815R
615
. o .
The d i s t i l l a t i o n column is used to separate dissolved gases
and water from the product methanol. This column is f i t t e d
with an overhead condenser system, two gas reboilers and a
steam reboiler.
. . ,
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The overheads from the d i s t i l l a t i o n column are partially condensed in the overheads condenser.
The remaining methanol
vepor is condensed in the l i g h t ends cooler at IO0°F. Such a
s p l i t cooling duty avoids subcooling of the methanol r e f l u x
more than is absolutely necessary and yet maintains very low
losses of methanol in the o f f gas purge from the secondary
methanol separation. This gaseous purge contains the remaining dissolved gases not separated in the letdown vessel and
l i g h t organic by-products such as dimethyl ether, aldehydes,
ketones, etc.
The l i g h t ends purge gas is compressed in the
l i g h t ends compressor and is used as part of the feed to the
reformer.
columns w i l l
compressor.
Light
e n d s from
three
separate
distillation
be recycled as feed through a common l i g h t ends
The d i s t i l l a t e is drawn as liquid from near the top of the
column. This product is cooled and passes to the fuel methanol storage f a c i l i t i e s .
A sidestream of fusel oil is extracted from near the bottom
of the d i s t i l l a t i o n column. The fusel oil contains the organic heavy ends such as ethanol, propanols a~d butanols
which are valuable as fuel. To remove these higher alcohols
from the d i s t i l l a t i o n system the fusel o i l , after cooling, is
pumped into the d i s t i l l a t e stream to y i e l d fuel grade methanol.
The bottoms water, which contains about 12 ppm alcohols, tim
bulk of which is methanol, is pumped t o the wastewater t r e a t ment area.
.
i
0815R
6/6
6,3
ENGINEERING DESIGN DATA
J~
Design dato pertinent to Reforming, Synthesis and D i s t i l l a t|on ts detailed in the Process Flo~ Otagrams immediately
following thts page, in the Equipment List beginning on Page
6/9, and in the Drawings following Page 6/22.
0815R
6/7
DRAWINGS RELATING TO METHANOL
SYNTHESIS AND DISTILLMION
TITLE
DRAWINGNO.
5530-213-Y-001
Methanol Synthesis
5530-214-Y-001
Methanol D i s t i l l a t i o n
5530-219-Y-001
Reforming
5530-219-Y-002
Reforming
EQUIPMENT LIST
5530-213-P-001
5530-213-P-OO2
Raw Gas and Methanol Areas - Overall Arrangement
Methanol Unit, D i s t i l l a t i o n and Synthesis - Plan
5530-213-P-003
at Base
Methanol Unit, D i s t i l l a t i o n and Synthesis - Plan
above 2Z'-O"
Methanol Unit, D i s t i l l a t i o n and Synthesis - Plan
5530-Z13-P-O04
above 38'-0"
5530-213-P-005
Methanol Unit, D i s t i l l a t i o n and Synthesis - Plan
5530-Z13-P-006
above 54a-0"
Methanol Unit, D i s t i l l a t i o n
vatio==
and Synthesis - Ele-
LIST OF CORRECTIONS
Equipment List
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METHANOL SYNTHESIS - AREA 213
| NCL&TUlill
t
- TYPI[
" CAPACITY
" t|i~l¢
" OPKN4TINI
PIIEIIUIOI
"rill4PRN&'rUII
IK
ll4 - l l 4 A T e r l l | d l , l~
eliCANIgON
liTItlEI.
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GI
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O - DNIlYI[
I - tlrlllN1r
AI=¢ = AC¢~1¢1101111¢1
-
EQUIPMENT L.IST
TEM
213-1301
,,
NO. REqUXRED
DESCRIPTION
3
Circulator
i
Single stage centrifugal
S - 6000 hp
Pi/TJ - Suction - 1394 psig/lOO°F
D - Steam t u r b i n e
T
213-1301-1
3
C i r c u l a t o r Turbine
T m Condensing
C
117,000 l b / h r steam
Pt/Ti/Po - 855 psJg/840°F/2 '' Hg Abs
213-1705
3
Flash Gas Eductor
m
Jet e j e c t o r
C - 4365 l b / h r with NW23.44
M - Carbon Steel with SS nozzle
Des P/T - S u c t t o n - 60 psig/lOO=F
Discharge - 370 psig
N3ttve gas @ 1394 psig, IO0°F
WIMW = 14.69
T
213-1614
Cold Shell Loop Interchanger
Shell and Tube
29,500 sq f t / s h e l l
Shell - Carbon Steel
Tubes - Ebrite
Des P/T - Shell - 1663 psig/3OO°F
Tubes - 1663 psig/320°F
T
m
SM-
08!5R
619
I
METHANOL SYNTHESI~ - AREA 213
C
EqUIPMENTLIST
ITEM
DESCRIPTION
NO. REQUIRED
W_arm Shell Loop Interchanger
213-1615
Shell
T
and
Tube,
2
shells
in
series
S - 14,800 sq f t / s h e l l
M - I s t Shell - Shell/Tube - C-I/2 Mo
2nd Shell - Shell - Carbon Steel
Tubes - Ebrite
Des P/T - Shell - 1663 psi9/515 °c
Tubes - 1663 pstg/570~'f
213-1616
Loop Start-Up Heater.
3
T N Shell and Tube
S - 1700 sq f t
Shell/Tube - C-I/2 Mo.
Des P/T - Shell - I020 psi9/9OO°F
Tubes - 1663 psig/9OO°F
Crude Methannl Condenser
213-161
T
m
SMDes PIT D-
Fin fan
23,350 sq f t bare area
Tubes - Stainless Steel
Tubes - i663 psig/250°F
20-30 hp e l e c t r i c motors
Loop Saturator Water. Heate,r.
213-1618
Shell and Tube
T
S - 21,480 sq f t
M - Shell/Tubes - Carbon Steel clad
w/304L SS/Carpenter 7 Mo SS
Des P/T - Shell - 930 psig/470°F
Tubes - 1663 psig/570°F
Methanol Converter
213-2207
T
m
Vertical,
Cylindrical,
catalyst packed
M - C-1/2 Mo
Des PIT - 1663 psig/6OO°F
Catalyst ICI Type 51-2
C
0815R
5/10
6
bed
METHANOL SYNTHESIS - AREA 213
.EQUIPMENT LIST
ITEM
NO. REQUIRED
DESCRIPTION
Crude Methanol Separator
213-2208
T - Horizontal, Cylindrical, double
barrel
S - I0' ID x 30' T-T top barrel
6' ID x 30' T-T bottom barrel
M - Shell - Carbon S t e e l ,
304 SS
l i n e d top b a r r e l
Bottom barrel a l i carbon steel
Des P/T
1663 psig/150°F
-
213-2209
3
Letdown Vessel
T - Horizontal, Cylindrical
mounted
w/demister
S - 8'6" ID x 30' T-T with 6" TK
demister pad
Demister - 304 SS
Des P/T - 150 psig/15O°F
0815R
6/11
METHANOL DISTILLATIONi iil i AREA
214
i =
EQUIPMENT LIST
ITEH
214-1103
NO.
R.EqUIRE,P
G " CAPAC~YV
• " 8lIE
PlY - OP~nPLTIIOIS PRKmlUmIKI
TEWOPIN mTU Ill(
HHA?llOlJ~l.
GI¢&milON
1Tt:~L
!1 " ITA~NIJZII
Qfll
L
C1 - C A l ?
1NON
0 - DIe|VII
IIW • I I l K I Q N T
&¢G
- A¢¢lilOllla
DESCRIPTION
3+3
Reflux PumE
T - H o r i z o n t a l , Centrifugal
M - Casing - Cast 3Leel
Impeller - Cast Iron
D - 100 hp, E l e c t r i c
214-1104
3+3
Bottoms,Pump
T - Horizontal, Centrifugal
C - 85 GPN @ 60 psi &P
H - Casting - Cast Steel
Impeller - Cast Iron
D - ]0 hp, E l e c t r i c
214-1105
3+3
Steam Condensate Pump
T - H o r i z o n t a l , Centrifugal
C - 330 SPH @ 20 psi ~P
M - Casing - Carbon Steel
I m p e l l e r - Cast Iron
D - 10 hp, E l e c t r i c
214-1106
3+3
Fusel 0 t l
T
C
M
D
-
214-1306
Pump
Reciprocating
3 GPM @ 60 psi ~P
S t a i n l e s s Steel
] hp, E l e c t r i c
L i g h t Ends Compressor
T 1 3 stage r e c i p r o c a t i n g compressor
C - ]29,277 SCFH
Des P/T - Suction - 1 psig/lOOl"F
Discharge - 370 psig/lOO°F
D . 1000 hp, E l e c t r i c Rotor
214-1619
3
Feed. Overheads Interchange.r
T
1
Shell and tube
S - 1945 sq f t
M - Shell/Tubes - Carbon Steel
Des P/T - Shell - 75 psig t o FV/3OO'F
Tubes - 150 pstg t o F~/3OO©F
0815R
6112
METHANOL DISTILLATION - AREA 214
EquIPMENT LIST
ITEM
,i= •
i
i
N,o. REQUIRED
DESCRIPTION
Overhead Condenser
214-1620
T
SMDes P/T -
m
D-
214-1621
3
Fin fan
30,500 sq f t bare area
Tubes - Carbon Steel
Tubes - 75 psig to FV/3OO'F
20-40 hp electric motors
Liqht Ends Cooler
T m
CSMDes P/T D214-1E22
Shell and Tube
15.39 MM Btulhr
1350 sq f t bare area
Tubes - Carbon Steel
Tubes - 75 psig to FV/3OO°F
2-15 hp e l e c t r i c mGtors
Methanol Cooler
T
CSMDes P/T D-
214-1623
Fin fan
8.79 1~
2200 sq
Tubes Tubes 2-30 hp
Btu/hr
f t bare area
Carbon Steel
75 psig to FV/300°F
e l e c t r i c motors
Fuse; Oil Cooler
Double Pipe
C - 0,13 NM Btu/hr
S - 25 sq f t
N - Carbon Steel
Des P / T - Outer pipe - 150 psig/3OO°F
Inner p t p e - 150 psig/170°F
T
214-1624
m
3
Bottoms Cooler
T
CSM-
m
Des
0815R
P/T
-
Shell and Tube
4.69 MM Btu/hr
390 sq f t
Shell/Tubes - Carbon Steel
Shell - 75 psig to FV/3OO°F
Tubes - 150 pstg/170°F
6/13
METHANOL DISTILLATION - AREA 214
(
EQUIPMENT LIST
ITEM
NO. REQUIRED
DESCRIPTION
214-1625
Distillation
No._.__~l
T 1
SMDes P/T 214-1626
Column Gas Reboiler
Shell and Tube
11,634 sq f t
Shell/'Tubes - Carbon Steel
Shell - 75 psig t o FV/3OO°F
Tubes
1663 psig/410°F
Distillation Column Gas Reboiler
NO,_____22
T
.
Shell and Tube
S - 17,145 sq f t
Shell/Tubes - Carbon SLeel/304 SS
Des/P/T - Shell - 75 psi9 t o FV/3OO°F
Tubes - 730 psig/520°F
214-1627
Distillation
Column
Rebotler
T m
CSMDes P/T 214-2210
3
Shell and Tube
125 MM B t u / h r
9470 sq f t
Shell/Tubes - Carbon Steel
Shell - 75 psi9 t o FV/3OO°F
Tubes - 75 psig/360°F
Distillation
Column
T
m
Valve Tray
M - Shell/Trays - Carbon Steel
Des P/T - 75 psi9 t o FV/3OO°F
21¢-2211
3
Reflux Drum
T
SMDes P/T -
Horizontal, Cylindrical
8'6" ID x 27' long T-T
Carbon Steel
75 psig to FV/3OO°F
C
0815R
0114
Steam
METHANOL DISTILLATION - AREA 214
EQUIPMENTLIST
x rEM
214-2212
,
NO......REQUIRED
DESCRIPTION
3
S_team Condensate Drum
T
SMDes P/T -
214-2213
Horizontal, Cylindrical
6 c ID x 13' long T-T
C~rbon Steel
75 psi9 to FV/3OO°F
Hydrolyzed Gas Separator
T
SMDes PIT -
214-2502
Vertical, Cylindrical
8' ID x 15' High
Carbon Steel w/304$S l i n i n g
775 pstg/320°F
Caust.tc. Oosing,S,et
T - Skid mounted
tank, pump
and
agitator for pH control {1% NaOH
solution)
C - lO0 GPH @ go psig discharge
Tank - lO00 gal
M - Carbon Steel, polypropylene lined
08]5R
8/]5
NQMI N¢LACUN
T " T Y P IE
•
• 85|il
- OP|IATINO
Pi|llUIz/
TICMPRNAT~IIR
M - MATERIA
L
¢1E- C:mlmmON IrrlEEL
II " ETAINLRII
IT[EL
¢| = CART INON
O * ONIVR
t~MEIOI4T
i C I~' " i I ~ ¢ E I C R I R I
PIT
REFORMING - AREA 219
C
EQUIPMENT LIST
ITEM
219-1101
NO. REQUIRED
DESCRIPTION
1+1
Fuel O i l Pump
T
C
H
D
219-1102
-
1+1
Reciprocating
4 GPM, ~P = 50 p s i
Cast I r o n
1 hp, E l e c t r i c
T.uP,bine Steam Condensate Pump
T
C
H
D
-
219-1301
Horizontal, Centrifugal
280 GPH @ 46 psi
Ap
Cast I r o n
10 hp, E l e c t r i c
Reformed Gas Compressor
T
S
C
Pt/Tt
-
3 Stage C e n t r i f u g a ]
19,100 hp
6.85 HM SCFH
240 psig/lOOOF
Po/To - 1394 psig/lOO°F
D - Steam Turbine
219-1301-1
Refm~ed Gas ComPressor Turbine '
T - Extraction
C - 228,113 l b / h r Steam
P i / T i / P o - Steam Turbine, 1500 psJg,
350 p s i g / 4 " H9 Abs
219-]302
219-1302-1
-
Centrifugal
120,954 ACFM @ 14.5" w . c . &P
H o u s i n g / I m p e l l e r - Carbon Steel
Steam Turbine
F_~.D.. Fan Turbine
T - Condensing
C - 2600 l b / h r Steam
P i / T i / P o - 350 psig/590OF/4" Hg Abs
0815R
900=F,
Forced D r a f t Fan
T
C
H
D
6/16
|:
REFORMING -
AREA 219
.EQUIPMENT LIST,
ITEM
NO. REQUIRED
DESCRIPTION
219-1303
Induced Draft Fan
T C MD-
219-1303-1
Centrifugal
233,562 ACFM @ 23" w.c. AP
Housing/Impeller - Carbon Steel
Steam Turbine
I.D. Fan Turbine
T Q Condensing
C - 7630 Ib/hr Steam
PIITi/Po - 350 psig/590°F/4 " HgAbs
219-1501
Reforming Furnace
T - Down f i r e d co-current
C - 293.88 MM Btu/hr
S - 58'6 = long x 47' wide X 35' high
Tubes - 312 t o t a l required, 13
tubes/bank, 4 banks/ro~, 6 rows
t o t a l 4.3" ID x 0.375 thick x
35' long ( p u l l bored)
M - Tubes - Manau~ite 36-X
C~talyst - I137 f t
on natural gas
reforming c atal 3st:
57-3 long
rings or equal
219-1601
Radiant Shield Boiler
T
m
CSMDes PIT -
219-1602
Vertical tubes in duct
20.88 MM Btu/hr
900 sq f t
Carbon Steel
1760 psig + s t a t i c h~ad/670°F
Steam Superheater
T
Horizontal coil in duct
C - 66.68 MR 8tu/hr
S - 6250 sq f t
M - 2-114 Cr 1Mo
Des PIT - 1760 pslg/llOO°F
0815R
6/17
REFORMING - AREA 219
(
EQU,I,PMENT L,IST
ITEM
N0. REq.UZRED
DESCRIPTION
219-1603
Reformer Steam Attemporator
C . 272,200 l b / h r , 1550 psig
Steam to 920°F by injection of
BFW
219-1604
Mixed Feed Preheater
Shell and Tube
C - 106.91MM Btu/hr
S - ]4,360 sq f t
M - Shell - 2-1/4 Cr 1 No
Tubes -310 SS
I n l e t channel refractory lined
"Des P/T - She]] - 310 psig/lO5OOF
Tubes -400 psig/950°F
T
219-1605
Combustion Air Preheater
Rotary
75.19 MR Btu/hr, 465,173 l b / h r
air
Des P/T - Air in @ 10" w.9./62 ° DB to 700°F
D - 20 hp e ] e c t r i c motor
T !
C-
219-1606
Flue Gas Boiler
T
CSMDes P/T -
Horizontal tubes in duct
71.13 MR Btu/hr
50,035 sq f t (finned)
Carbon Steel
1760 psig & s t a t i c head/670=F
(
0815R
6/18
REFORMING - AREA 219
E~UIPMENT LIST
ITeM
NO..REQUIRED
DESCRIPTION
219-1607
Reformed Gas B o i l e r
T CSM-
Firetube
]16.69 MM B t u / h r
2920 sq f t
Shell - Carbon Steel
Tubes - Carbon Steel
Inlet
channel
&
tubesheet
refractory lined i n t e r n a l l y
Des P/T - S h e l ]
1 7 6 0 psig + s t a t i c
head/660=F
Tubes - 300 psig/660°F
?19-1608
HP BFW Heater
T CS M-
Shell and Tube
28.23 MM Btu/hr
4310 sq f t
Shell - Carbon Steel, SS clad
Tubes -304 SS
Des P/T - Shell - 300 psig/470=F
Tubes - 1760 psig/4OOOF
219-1609
Reformed Gas Cooler
T CS P/TD-
219-1610
Fin fan
121.18 MM B t u / h r
11,200 sq f t bare area
Tubes - 300 psig/425°F
10 x 30 hp e l e c t r i c motors
Turbine Steam Condenser
T - S h e l l and Tube
C - 140 MR B t u / h r
S - 5200 sq f t
M - S h e l l - Carbon S t e e l
Inhibited
admiralty
bronze
Tubesheet - 90/I0 Cu/Ni clad
Carbon Steel
Des P/T - Shell - 75 psig + f u l l vac/350°F
Tubes 150 psig/IZO:F
0815R
6/19
REFORMING - AREA 219
<i
EQUIPMENT LIST
ITEM
N0. REQUIRED
DESCRIPTION
F i r s t Interstage Cooler
219-1611
T
C
S
M
-
Shell and Tube
15.53 MM B t u / h r
1830 sq f t
Shell - Carbon Steel
Tub~s - 304 SS
Des PiT - Tubes - 850 psig/3OO°F
Shell - 150 psig/170°F
219-1612
Second Interstage Cooler
T C S M-
Shell and lube
15.28 MM B t u / h r
1780 sq f t
Shell - Carbon Steel
Tubes - 304 SS
Des P I T - Tubes - 850 psig/3OO°F
Shell - 150 p s i g / 1 7 0 ° F
;=
219-1613
Reformed
6as
Compressor
L'.
T
C
S
M
Des P/T
-
Shell and Tube
16.44 MM Btu/hr
1850 sq f t
Shell - Carbon Steel
Tubes - 304 SS
1560 psig/3OO°F
Shell - 150 psig/17O°F
t
!
.i
!
219-2201
Steam Drum
T m
CSMDes P/T -
Horzontal, Cylindrical
Normal - 236,700 lb/hr steam
52'6" T-T x 6' ID
Carbon Steel
1720 psig/650°F
C
0815R
6/20
REFORMING - AREA 219
EQU,IPMENT LIST
ITEM
NO: REQUIRED
DESCRIPTION
219-2202
Reformed Gas.Separator
T _ Vertical,
Cylindrical
wlSS
demister
S
6'6" ID x 12' T-T
M - Carbon Steel W/304 SS lining
Des P/T - 300 psig/2OO°F
219-2203
Reformed Gas Compr@ssor Suction
.Separator
T
Vertical, Cylindrical w/demister
6'6" ID x 12' T-T
M - Carbon Steel w/304 SS lining
Des P/T - 300 psigi~OO°F
219-2204
First Inters.tage Separator
T . Vertical,
Cylindrical
w/SS
de~11sLer
S m 5'6" ID x I0' T-T
M - Carbon Steel w/304 SS lining
Des P/T - 850 psig/3OO°F
219-2205
Second Interstag e Separator
T m
SMDes P/T -
219-2206
Vertical, Cylindrical
5' ID x 8' T-T
Carbon Steel w/304 SS lining
850 psig/3OO°F
Reformed
Gas
Compressor
AftercoG1er Separator
T . Vertical,
Cylindrical
wIGS
demister
S
4'6" ID x 8' T-T
M - Carbon Steel w/304 SS lining
Des P/T - 1560 psig/3OO°F
0815R.
6/2i
m
REFORMING - AREA 219
.
EQUIPMENT LIST
ITEM
219-2207
NO. REQUIRED
DESCRIPTION
1
Fuel 0 i l
T S MDes P/T Acc -
219-2401
1
Day Tank
C y l i n d r i c a l , Vertical
20'ID x 18' T-T
Carbon Steel
Atm/Amb
I n t e r n a l Heating Coil
Flue Gas Stack
T - Self-supporting,
Vertical
Cylindrical
C - 11.02 MM ACFH f l u e gas w/mol wt
= 27.37
M - Carbon S t e e l , Gumite lined
S - 80' tall
x 10' ID
Des P / T - Abmient/335°F
\.
0815R
6/22
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:o
-'o
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i
I
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I
i
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_LI
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,
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I
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I
i
I
!
[~0.
".evxszoq~
DESCRIPTION
'~ [~ I=letAt, UPO,itE
|l
BY
~H.J,S,!
~.W. i
....
CHK. DATE NO,
"Z,q,jrl
&.lmifl
REV[SXbNS
DESCRI[PTCON
BY " CHK. IDATE .fJH_e.ND.
REFERENCES
TITI-e~
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1
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L II
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PlPEWA.Y
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~,TE
r_.,,I~.EI~E,~I.,,15 ,S...'~_['. A,,~cE T,',~IU-..t.- F 0 2 E/,,,.Cr'i H~'~-,~JLE
LXE.NI' ~_C I ~'l i "~'';-~'~'E ~"
DavyMcKee
ENGINEERS
AND
CONSTRUCTORS
TITLe
IAI
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5530-
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l•I ANO. p R e ~ . RnESCRIPrION
~.vte~0
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nEViSmKS
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SECTION 7.0
,OXYGENt NITROGENAND COMPRESSEDAIR
(Areas 101, 102)
7.1
DESIGN BASIS
7.1.1
Three air separation plants w i l l be provided. The capacity
of each plant shall be 2500 STPO of 99.5% purity oxygen by
volume.
7.1,Z
Oxygen required for reaction with steam and coal w i l l be supplied by the three air separation plants at 75 psig and 257°F.
7.2
PROCESS DESCRIPTION
7.2.1
Air_Separation Plants .(Area I01~ Dw9. 5530-I01-Y-001)
Oxygen w i l l be supplied by three air separation plants. Nitrogen from the air separation plants will be used for blan-keting, pressuring lock hoppers, pneumatic conveying and
backup for instrument air.
Liquid oxygen and nitrogen storage tanks plus vaporizers are
also provided in the air separation area. These are provided
f o r emergency use during unscheduled shutdown of one or more
of the three air separation plants.
7.2.2
Nitrogen and Plant Air S~stem (Area 102, Dwg. 5530-I02-Y-001)
Nitrogen from the air separation plants is compressed and
cooled to 105 psia and lO0°F in a two-stage compressor, and
is then distributed for use in pressurizing coal feed and ash
lockhoppers, conveying char and ash, and purging s i l o s .
0816R
7/1
Instrument and u t i l i t y a i r is supplied from a u t i l i t y air
package which compresses 180,000 scfh of air from atmospheric
conditions to 105 psta. The compressed air is dried in a
desstcant type drier to a -40°F dew point. The drier is a
dual unit, one section of which can be regenerated while the
other sectton is dwi~lg. Operation is completely automatic.
A ] t n e from the co~,qpressed nitrogen system provides emergency
backup f o r the instr, m ~ t a i r system.
4i
7.3
t
ENGINEERING DESIGN DATA
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Design data pertinent to the air separation plants and n i t r o gen/plant a i r systems is detailed in the Process Flow Diagrams immediately following this page, in the Equipment List
beginning on Page 7/4, and in the Drawings following Page 7/6,
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0816R
712
,DRAW,INGSRELATING TO OXYGEN~NITROGEN~COMPRESSEDAIR
_ Drawin~ No.
5530-101-Y-001
5530-102-Y-001
TITLE
Air Separation Plant
Nitrogen/Plant Air System
EQUIPMENT LIST
5530-]02-P-001
Air Separation, Plant
- General Arrangement
5530-102-P-002
Air and Separation, Plant Air and Nitrogen Systems Plan
5530-102-P-003
Air and Separation, P:ant Air and Nitrogen Systems Plan
0816R
7/3
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AIR SEPARATION PLANT - AREA 101
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,EQUIPMENTLIST
ITEM
DESCRIPTION
NO...,,RERUIRED
Air Separation and Oxygen
Compress,!.on Package
101-2501
This system ts to produce 2500
STPD of oxygen with a purity of
99.5% by volume. The oxygen is
to be de]ivered at 75 psig.
£
0816R
7/4
NOM Ii NCt, ATIJR It:
T - TYPE
C -
CAPACtTY
S • ll~K
P/T - OPI~RAI'ING
PR;iIURE/
Tit MPI~II ATUII[
NITROGEN/PLANT AIR SYSTEM, - AREA 102
EQUIPMENT LIST
ITEM
IOZ-1301
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MATER|AI.
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ACeI[IIIOII|
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DESCRIPTION
REQUIRED
First-Stage Nltrogen Compressor
3
Centrifugal
1025 hp
8,820 ICFM
0.5 psig/60°F
30 pslg/315°F
0--- E l e c t r i c
T
SCPi/Ti Po/To
102-1302
Second-Stage Nitrogen CompressRr
3
T ~e Centrifugal
S - 1030 hp
C - 3,560 ICFM
Pi/Ti
25 psig/1OO°F
Po/To - 90 psig/355°F
D - Electric
102-1601
-
F i r s t - S t a g e InterF. o o l e r
3
T C S M-
Shell and Tuke
6.52 MM Btulhr
Z,800 sq f t
Shell - Carbon Steel
Tubes - Carbon Steel
Des P/T - Shell - 50 psig/350°F
Tubes - 75 psig/150°F
102-1602
Second-StageAftercooler
3
T - Shell and Tube
C - 7.60 MR B t u / h r
S - 3,000 sq. f t .
M - Shell - Carbon Steel
Tubes - Carbon Steel
Des PIT - Shell - 75 psigll50°F
Tubes - 200 psigl3OO°F
0816R
7/5
NITROGEN/PLANT AIR SYSTEM - AREA 107
EQUIPMENT I.,IST
ITEM
DESCRIPTION
NO. REQUIRED
Utilit~ Air Pac,kage
102-2501
This system is to produce
180,000 SCFH of dry air (-40°F
dew p t . ) at 90 psig.
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0816R
716
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ENG~IEERS AND CONSTRUCTORS
SCALE t aw | O I T
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5 5BO-IO2-P-005
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SECTION 8.0
UTILITIES
(Areas 103, 300, 30l, 30Z, 305, 309)
8,1
PLANT STEAMSYSTEM(Dwq 5530-305-Y-00]
Steam for the entire plant is supplied from three different
plant areas, and at several different pressure levels, as described below.
8.1.1
power Plant (Area 300~ Dw9 5530-300-Y-00)~
o
DesignBasis:
The primary power production f a c i l i t y for the process
plant will be a conventional pulverized coal fired and
steam turbine generator system with three boilers and
three steam turbine generators. Its maximum design capacity w i l l "be 2,700,000 pounds per hour of htgh pres-
sure steam at 1255 pstg and 165 Mw of e l e c t r i c a l power.
o
ProcessDescription - Steam Generation:
A fuel supply consisting of a mixture of coal and char
ts received from the process plant, and is transferred
by conveyor belt to the coal bunker. The coal bunker,
is a silo type storage device which supplies fuel to the
pulverizer f o r reduction of the parttcle size of the
fuel mix to a fine powder. The powder is mixed with
preheated combustion a i r and injected into the boiler
where i t is ignited. Boiler exhaust gases are circulated through heat recovery devices which preheat air f o r
combustion and preheat boiler feedwater,
f
1058R
8/1
Part of the steam produced by the boilers is utilized by
the steam turbines for production of electric power, and
the remainder is sent to the process plant as high pressure steam.
The steam turbines selected for this operation are extraction type units which allow removal of part of the
steam from the turbine after some energy has been utilized. The extraction steam is
plant as low pressure steam.
sent to
the process
Ash from the combustion process is removed from the bottoms of the boilers, and from the baghouse exhaust gas
cleaning unit, then pneumatically conveyed to a r a i l car
loading station,
8.1,2
Reforming (Area 219)
o
Design Basis=
The reformer is designed to recover heat from reformed
gas to produce 236,700 pounds per hour of high pressure
steam at 1500 psig and 900=F. In addition to the process requirements of the reforming reactor this steam is
used for turbine drives in the methanol synthesis area.
A common steam drum is utilized for the steam generation
boiler and superheaters using natural boiler feedwater
circulation.
o
ProcessDescription:
Steam is generated by recovering heat from the reformer
flue gas using a radiant shield boiler.
This unit forms
a vertical waterwa11 screen across the entrance to the
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main convection duct, and performs an important function
in protecting the steam superheater from the cavity radiation of the reforming furnace rear wall. The radiant
shield boiler comprises a vertical natural circulation
system connected to lower and upper horizontal
headers.
The steam generated in
the boiler
is
water
then
superheated in two sections~ a high temperature section
and a low temperature section.
The superheater tube
bundles are arranged horizontally to permit drainage of
the coils.
Most of the exit steam at 1500 psig and 900°F goes to
the
steam turbine
pressor.
uses.
dr ,er
on the
reformed gas com-
A smaller portic~ is exported for other plant
Some steam is extract~ ~ from the compressor tur-
bine at 350 psig for use on other drives in the methanol
synthesis area and the remainder is condensed.
8.1.3
Gasifier Waste Heat Boilers (Area 206)
o
DesignBasis:
Each gasification train includes a waste heat recovery
section capable of producing 152,814 pounds per hour of
high pressure steam at 855 psig and 840°F for use in
steam turbines.
Steam drum internals are designed to
minimize entrainment losses. The output from each waste
heat recovery unit is manifolded into a common steam
header with suitable valves and controls.
o
ProcessDescription:
Steam is generated by recovering heat from gasifier raw
gas.
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The raw gas leaves the gasifier and enters the
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I'
waste heat recovery unit. This unit contains additional
steam boiler tubes, hlgh and low superheater sections,
and a boiler feed water heater section.
(~,..
The waste heat recovery unit on each gasifier acts as an
individual
steam generator, and is tied into a common
855 psig header. The steam is used for the steam turbine drivers on the process gas compressors.
8.1.4
Condensate
All condensate is returned for reuse.
Three deaeratinglheaters
are provided for the process area
steam generators, and three are provided with the off-site
boilers.
Demineralized water makeup is supplied from the raw water
treatment area as shown on Drawing No. 5530-301-Y-002.
8.2
ELECTRICAL POWERSYSTEM (Area 309)
8.2.1
Desisn Basis
Electrica] power for the plant and associated f a c i l i t i e s is
supp]ied by an in-plant
generation station
consisting
of
three equally rated steam turbine generators. The generator
outputs are transformed from ]3.8 KV to 69 KV. A single c i r cuit, 161 KV, transmission line to the Beluga Power Company
is provided for startup and standby purposes. The generators
and u t i l i t y power are paralle]ed in an outdoor 69 KV switchyard,
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Power for the mines is transformed to 161 KV and transmitted
on a single c i r c u i t overhead transmission llne. One single
tap type substation is supplied at each mine. The generation
station load is normally fed from auxiliary transformers connected to the generators,
Power for
the remaining plant
loads is distributed at 13.8 KV from double-winding secondary
• ,,,
,
transformers.
The total power requirement for the proposed f a c i l i t y is estimated to be 165 megawatts, detailed as follows=
1.
Coal Area
2.
Gasification & Gas Prep.
16 MW
49 MW
3.
Water
15 MW
4.
Lights
5 MN
5.
Mine
50 MN
6.
7.
PowerHouse
Miscellaneous
15 MW
15 MW
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:
8.2.2
Electrical System Description
The electrical system consists of three major load centers:
I.
Power Plant
2.
Capps and Chuitna Mines
3.
Process Plant
The total power requirements for these loads have been estimated to be 165 megawatts.
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t
L.,
Power Plant:
Three steam turbine generators supply prime power for
the f a c i l i t y .
A single circuit, 161 KV transmission
line to the Beluga Power Company and 69KV to 161KV
transformer is provided for start-up and standby power,
The 13.8 KV output of the three generators is transformed to 69 KV and paralleled with the Beluga Power
Company in an outdoor 69 KV switchyard.
Power for the power plant operating is normally provided
from three 7500 KVA auxiliary transformers. A source of
standby power is provided by one ID,OOO KVA transformer.
0
Transmission Line to Mines
The power to the Capps and Chuitna mines is trensformed
from 69 KV to 161KV and transmitted by a single circuit
transmission line. There is a tap type substation located at each mine. The step-up transformer feeding the
transmission line is rated 70 MVA and is equipped with
automatic load tap changing equipment to provide acceptable voltage regulation at the mines. The 161KV transmission line runs alongside the railroad corridor.
o
Process Plant:
The power requirements for the process plant are estimated to be IO0 megawatts. Power for use within the
process plant is transformed from 69 KV to 13.8 KV by
three transformers rated 50 MVA each. In the event of a
sing]e transformer failure, the two remaining transformers have sufficient capacity for the entire plant
load, when auxiliary transformer coo]ing is utilized.
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The main 13.8 KV distribution substation for the methanol plant consists of three secot,dary selective switchgear lineups equipped with automatic transfer systems.
Each switchgear lineup operates with the t i e breakers
normally open.
Substations
The majority of the 480 volt and 4160 volt substations
u t i l i z e a secondary selective distribution system with
automatic transfer. Where reduced levels of r e l i a b i l i t y
and longer outage times are permissible, a radial distribution system may be used. The present design includes twelve 480 volt radial
substations, t h i r t y - f i v e
480 volt secondary se]ective substations, two 416D volt
radial substations and five 4160 volt secondary selective substations.
~
Transformers for the 480 volt sub-
stations are rated 1000 KVA and transformers for the
4160 volt substations are rated 7500 KVA. Both are
equipped with auxiliary fan cooling.
I D
P
Equipment f o r the 480 v o l t and 4160 volt substations is
installed in prefabricated bu;ldings.
The substation
vendor supplies and i n s t a l l s
including v e n t i l a t i n g
all
equipment,
necessary accessories
lighting,
annunciators
and a DC contro] power system as required to operate the
substation.
The 480 v o l t
prefabricated
substation
bui]din9s are installed on modules at the point of
module fabrication.
Where an entire 480 vo]t substation
is not required on a module, individual motor control
centers are installed on the module. The 480 volt substatiUn wirtng is completed to the extent possible before the modules are shipped to Alaska.
substations will
4160 v o l t
be shipped directly to Alaska where
they will be mounted apd wired.
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All
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All motors larger than 3500 hp are rated 13,200 volts, 3
phase. A l l motors in the size range of 200 hp to 3500
hp are 4000 volts, 3 phase. Motors smaller than 200 hp
are 460 v o l t s , 3 phase except f o r f r a c t i o n a l horsepower
motors which are rated 230/115 volts, single phase.
8.3
RAWWATERTREATMENT(Area 301)
All water used in the plant is drawn from wells.
requirements f a l l into three categories of usage:
2.
General Plant and Potable Use
Boiler Feed Water
3.
Cooling Tower Water
I.
The water
A different type of treatment is required in each case to
supply water of suitable quality for each use. The several
requirements and treatme~ts are described below.
8.3,1
General Plant and Potable Use
Raw water will be softened by the "Cold-Lime" process, neutralized, and chlorinated before distribution.
),
J
Estimated requirements for this use category are:
GPM
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Plant Processing Uses
Pump Seal gater
Make Up to Coal Dryer Scrubber
L,co Shop
real Handling & Storage Area
Drinking and Sanitary
5OO
175
255
5O
40
Miscellaneous Uses
TOTAL
140
15
1175 GPM
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,!
%.!
•
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Water treatment f a c i l i t i e s using the "Cold-Lime" process w i l l
be designed to produce up to 1400 GPM of softened water to
account for peak demands and to provide a nominal excess capacity.
i
8.3.2
Boiler Feed Water, (Owg 5530-302-Y-001)
'4
Water of boiler feed quality is required for producing high
pressure steam, and for use in the gasifiers and reformer
waste heat recovery boilers.
Due to the presence of high concentrations of silica in the
wel] water, make-up water for boiler use is f i r s t softened
using the "Warm-Lime" process for partial removal of silica,
and then is demineralized using a combination of cation and
anion exchange beds.
Water treatment f a c i l i t i e s w i l l be designed to supply up to
2600 GPM of make up water to the high pressure and process
area boilers. This includes an a11owance for nominal excess
capacity.
8.3.3
Coolinq Tower Make-Up Water
Cooling tower make-up water w i l l require alkalinity control
and chemical additions to prevent scaling and bio]ogical
growth within the recirculating cooling system. These requirements are accomplished by adding appropriate chemicals
directly to the cooling tower basins. Sulfuric acid is added
for alkalinity control.
Inhibitor and dispersant chemicals
are added for scale control. Chlorine is added for control
of biological growth.
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The cooltng tower blowdown w i l l be discharged d i r e c t l y to the
e f f l u e n t storige pond f o r blendtng with the treated process
wastewaters f o r f t n a l discharge to Cook I n l e t .
8.4
COOLINGWATERSYSTE.M(Area I03~
Cooling water is supplied through a forced draft, open recirculation coollng tower system. There are flve cooling
towers. Each has Its own set of recirculating cooling water
pumps, and each represents 20~ of the t o t a l plant cooling
water capaCity.
Each tower has two speed reversible motor
fan drives and adjustable louvres - a combination which provide~ maximum f l e x i b i l i t y
in adjusting to changing climatic
conditions.
Each tower Is designed to cool 66,000 gallons of water per
minute from 95°F to 65°F with a 7° approach to the wet bulb
temperature. Design summer time wet bulb ten~eraure is based
on 69°F which w i l l not be exceeded more than 5~ of the time.
(Date Source: The Fluor Co.).
CoDlin9 tower water is distributed throughout the plant by
means of distribution headers. To prevent fouling on heat
exchanger surfaces, reduce scale formation and prevent the
growth of algae, provision Is made for the addition of certain chemicals such as chlorine, s u l f u r i c acid, dispersant,
etc.
Makeup water is supplied from wells, and controlled blow down
will be sent to the wastewater treatment area prior to discharge from the plant.
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