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 ~, ..,. . "."L'~,~.,,.,-w ............................... 4 , , . , ,,~,,' '"'., " , ' - ' ' • °"," ......... ,,. , .............. :. CO + 2H2 ~-~ ~ CH30H C.., 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. :,.." :w ;" 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. !L. ": purged to maintain the proper inerts level in the loop. This ( :t, purge is used as part of the reformer feed and fuel. ii , • The remaining gas is recycled through the circulator compressor and the Interchangers back to the converter. The makeup gas .?,:'i' ';' 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. { x. 0815R 612 • ,t .,.. 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 L ~ yi.: ~. • ,, .'i" 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. i i~!¸ 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. .) ! 0815R 6/3 ,i / q~ ~ I * . . . . . . . . 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. C ;. 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. . . , C 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 Reads Should Read 213-1301-1 C 117,000 39,000 214-1621 T Shell and Tube Fin Fan Shell--310 Tubes--400 Tubes--3]O Shell--400 219-1604 C Item Des P/T 219-1607 T Horizontal Vertical 302-1103 C D 200 350 670 1,065 0815R 618 t~ .,I ,.,,-,-,, .."l'.!!]!!!!!!!l.!l'~t.!l.l~.~ ,~l;l~.l.tI1.1:1:,:1.~,.~,.~,:,Zi 87RE~ DE~RI~|ON l J J 11 t l I ~ J. [ ~ J.J. LJ. ~.~ [ J.Z~ ,,,-r"l P £ ~45 [ 2' t'~-220",~ 2L3-1616 CONVERTER HBTER f- 213-1615 213-1618 INTERC'-IRNP,ER COL~ HATER HERT[R i, a J / I ~s'llm4i s I C -'l)'-i | ,;,o-v-oo~ ~F ~, e,el a I Iz,',lzzoTl' " I | 21o.-'t-ool ~ SnTW~T,',~ NMF..q i I 2.,,~ooi 14 vo t o ~ ~s ccL.~,,, ~Eoazc. L J 214-Y-OOI . i 213 CIRC" LURt RF.OOILER I A¢|II4| OWlICISSI'TION i¢~ I ..~ 2 ! I I : I r i ii ~,-rm'ltill I tl ~ I ! !,LLL ',='F'=rL t [ I mt L L I L L !, f .~-~ . . . . . |. ]i 213-|6t~ CRUDE NETHRNOL CONDENSER 213-1614 COLD SHELL LOOP INTERCHN~IOER 213-ZE0~ CRUDE HETH~NQL SEPARATOR 2t3-2209 LET~OHN VESSEL 213-1~05 FL~SH GAS EDUCT3R | i PUR~E O~S.I ~|~ Y OOt TO REFOI~'~q F ' L ~ " ;''':':z=-t''u= J , )-----~ i II, - L.... "I : - - I===l=~osl = I C01~INED PLm~ A I - ~ (! ='~=~'-= To 1=131t==zj 3 I ";- i:,zr,]z=ot-ll := ] i ¢ IRCULP,TOR 213-130t-! C2 RCUL~TOJ~ TURB%NE NOlrZz lrlzk I~.k~Io~ i=,mzn~ of DAVYMcKEE I~OiR.zQUllQN.. I l mz.m.mlk.., l=~ld w t,.m~=. 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(~ ' D 214-2502 CfiU~INQ SET I r i i i Iz-lz,~,fl 3] i u I~z411esgl :b I t*'J ,[ I r fl )Bm_ ,/v i .I r 1~1.4111o=1,N L2i~,¥-oo1 ~ LooP CONYERTEROR9 TO DXfrgTZLLATXONCOLLIHNItESOttER 1 L2|3-~-OOl ~t LonP CONVERTEROR8 TO COL[] SHELL XmERCH/iNQF.R I.~l*lte,~;I " I'''IL J ~-~|O-Y-OQI ,J- HYOROLY2EOOA8 TO OIBT|LUtTXON ¢OLtJ~l nrcm~l.ER 2 L L~Y-ooi .L¢_ ¢o~e,sa're 214-1103 REFLUX PUH?- 214-1104 BOTTOHS PUHP 214-1108 m , FUSEL OIL PUHP llczc3L _m -3 IIIII ----,4- ~-I~. I i II I L! i ! ! i,I.I.~ ,,-r'~, ! ! ! [ ! ! ! ! ! ~. _! LI~0ILIER o~. -----4% 2:4-~.b'2~ ~I"STZLL,~T Z0N C'~L.,~.I.IN P~,~S ZZ.~-22~.0 ~ :~::l~l CCL~JI,~ 2:4-~.S24 BOTT~J4S CQCI...~ 2:4.-IG22 HE THP.",~-'L CL-'CLr."R i 2%¢-1623 ~ - - ~ L ~-ISr=O %Llg:l u2 214-*-62"; ,"-"-'ST [LLAT I C..~I 214-2:*'2 5TF~H RE'~31 ~LS.q {~LLq ~ PIIC{I~. lq~'l'll~Ul3. TI~ l'rl:ll/iG~ 1 I ! ~.-~_/ ° Y /-'--'-~ i I | ' ' 'I az;-,-~ ' ! :..~. ,+ .... ~,, :, F : ~ ,, ,, -~ ¢;~]~[]I~TE :..... 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" ~ , . ~ . L R :'£ ;.,~R~ TOR t C,t'! R E F ORM('I.! ( : n S CO~,;~F~F '..5OR FF'IER COGL, L R : r. : i:+q C ~ , ~ . = r l ' Y.CO~; ~R6: P£.:" ,.. • ~'-' • ~. ! ' i ~'~ • 1 C~R i~it ~t:~ "2 :, i 7 ;i • • .~-~ !.i ..,< .+, :-3 it, -,. ...... .... ~| I t.-,:,t-,.:_:_:'.__l .T,L ! : ° ~i ¢ O B p a I ~ T I O M . I t I m l t m t be I~m¢~ nat I*~m* C I R" IP" r'CI~-P-'- -rl IL ~w~dml~d Qr t a ~ l W :;, ~ q I " lO I &'!),~. :. lIO~l T ¢ 8 Plf 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. l i b * ImTdlLINL01[IJlII I T I l [ g r L GI GAIIT iNON 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 ,~o'.c;' :o -'o 8d-d' r ; i ii 7~-d' so: o" II ~o'-o" i ~o'=f e, t ri"l I I1 ; ,,,] ] , so'.d' t If I i I !_ I i 'i'I ~s:o" _LI I I,,I r-- PIPE~ , | i I ,.,F 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~ , I .I 1 ! i I I I,, L II ! t t I i , PlPEWA.Y , ,, ! ! : ' } II ! ] ~,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 Z,,~.EA,~.. 5530- 'ZI3- P - 001 l/o\l i. m, G e,A"t'.~ ~ ~-~ ," ~.5'= I~O I ~ ~ \ w I -" ._ S ~ v i s z o . s l•I ANO. p R e ~ . RnESCRIPrION ~.vte~0 I nEViSmKS BY CHK. iP~TI~ NP. ,.pEg'CRIPT|OH w,,l~ ll.$.~_! o ! S S U L " ~ I ' ~ . ' E e P o ~ T .... BY ~ C~F. DATE'DNg.NO. REFERENCES TITLE #/zolll ~ I m m m . lT>'p L. • , \ ,. ::% , \ j ' I> 'Z14- 2,S~Z . .. ,, !, ] % // \ r \ Q / oJ / t |l '2.t~, .... • \ 't ! ) '1'"' \\ _~ _... "! tn ' i [ • .~ • l r ~ - Jr..is -> 21~- .)- : L_ CI.IF.liT G I~i/PLACP-~ ' DavyMcKee . r'~ ....... ,,r i. .. ENGINEERS A N D CONSTRUCTORS BY nit4=• ' il:X,O I , . i,~,',~. BATE s,,.E 1" :, ~' !TITLE MG.'I'HAi4OL, Ul,.i i T ' ~ | ~ T I L L A T I Q N ~, ,~'I"N'rHF..,~I~ .I " .~o-'LI3- P-oog ii i I .,v- DRAN|NG NO- A ...... ii:! .~ ,"IO 'Zi4. b ~ 1 I..,.__ C) ! /i... < ! i' I i L ,.ol r I _@ I -I --. 4...-,.- RE¥1SZOkS I i v.... t~,~. [ , ^ ~ |n.o.I REVIS~LONS I "V ;CHK- IBATE BaNG .ESCRIrTIO. I A I PR~L. R LvI~.W/ IW.J.~J II.S.611 0 Ilss.E:oT~_~.*I.~,~:po~- I ~ ~#.'11 l,o.I nEScRZrTIO. !c!,~....v,,s,:~ a ~ ,I I~<,,,,, I I ,~.N-. t ~ ! ..... /i D J ~-(~ ~ • IC=15 •'l° o .. " I "l t ;) ".~~ .... .. •7 . r ~ - ic.,iI~ @.- / '2,13. I~=L~ ~ ' ". . *. . . . . . : Imm, ! •. Ic~'P I I .: I.^ee. I "~. 17tzo/et - :- CIRI/PLACEP-- ~ETI-~ANoL UNIT OISTII..LATIQH ~ ~YIwI'I'i,4f,, -~IS Pu,~N ,',.~;,o,,,e 9,2'..o" ~ ~ a y McKee ID I .NO,.--~~N, COHSTRUCTORS V IscA-e t" : I ~' IIRAIIXWSWO. l 55~o-"L~-P-oo3 m r i \, / / .I f,' /;" . . . . . . . . . . . ~ . . . . . . . . . . . . . . . . ° . . . . . . . . . . . . . . . . . . . . . . . . . ~ : 0"1 !, i I . I ! i i , i ' 1 REV][S|OH$ "' REV lS|DHS ~'il~-I DESCRTPT[ON B Y . CHK. DATE NO, DF_-q__r'R|PTI[OH A IPREL.R[VteW d.J.$. 11,5-81 0 Is,~E~T-c~"~t,~.~,,.'ll~r.lp~.'I" " 1311~'iI"t~'L- UPDA,'i'~ C i | ~W ~-~,~1 I lt(vlse~> " ,, ~ , IrN~' BY ~ CHIC.' DATE! I)Nl;~.N0.. PI~'I REI:EREHCE5" ' TITL'E nJ ;~ ~I l_ ,, il ~i,i.~ • i~i ~, ~ i~ ~ ~ ....-" .. ", "% t . . . . o-/ . . . . . . . . . t , / / ~° - ( )-I ~I.IENT i DavyMcKee Ct&I/PLACER. ENGINEERS A N D C O N S T R U C T O R S ill [ --+ __ .lls-+, ;: i tOES |Y iORMN ~rr '~/.~ • /,rr' DATE tm.++ ' "CAL.+ L" = tO' ' tvt~.T~iAI~ o L U N I T I I mev, ]RAHING NO. OISTILL.A~TIQN ~r ,~YNTHF.~|~ PLAt4 ABov~ ~8'- o" i a . i " 4 , . . , ~ "at I I ,,#]• q.tZ I .q I ~'?..i, t.: i 5,: i , e . ;: ( o i? ..:." i "?.t4.- IG?.O i 1~,9.2. it.:blENT CIRI/PLACEP,. i --.;-,_ , pEs DUN CK.IB APP APP ~ATE ll~olar l TITLE METRANOL UNfT OiT~'rlLLATI ON ~ ~'¢14"rH~.~lS PLAN A~oV~. 5 4 ! 0 ~ i i i Ill DavyMcKee ENGINEERS AND CONSTRUCTORS SCALE i n= IO t . . . . . REV. DR.~HIN6tO. 5S~o-9.1~-P-oo5 ..u S t I q %'- 0" ~ 14-t~'z'E 'ZI ~.-I~,'?.. I LI 54.;o" mS I lye, - - , o , . _ . ?..14,,, IG?.,~ ?.14- I G'LC.., _o ?-14-IG'~.7 0¢ 2 I~j~e'Z'~ ,,dr 'T.L. - o o %i4 - %"¢i'?- II i __ u - , , , I m ~ . ~ *1~111 ;.... -L-L_ ........ 1 L_ .. L J_ I o. ; 'Pl r - - I'114.. I~2.0 9.15.1d, I ~ ' "i .? _ "'1 ~ W i * I~-~ro15 ~.~ ~i I / ... m ,~. ,. ,~,~.: m i | I / / \ / 'i J J .-~., -.~ , J i ,! I LL ¸ L I I r. m C I RI/o LAC,~.l~ ¥ rE ;TLE ~'T~A~o L. U~'~ OI ,STILI.A'I"IGH Pi-,5,.,'tlTHE£~I.5. El. EVATIOI'4 DavyMcKee ENGINEERS AND CONSTRUCTORS MNKi4G NO. 55~o-~1~- p.oo~ i 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 :! 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, ':i 3 #,. L 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 Air and Nitrogen Systems . , , . _ i "*' ,,.-i,!ii!i lilll~Ll,1~l,!,q,1~q,l~t1.1~I~I~I~I1.t_~I.~1.11~I~I l i I.. l .* , II . I ' • Jl I _ I _ ~-!i"!j !,.! !! l ! ! !!~!!LL~!~ RIR SEPRR~ ~IOll PRCI<Agl ' REVERSINO EXCHRNgERS I [ IO2-Y-O0! J'CO'PRESSOR I I . ~ r ~ K - v ' i n A T i ~ l . TO |OAIN GAS|F |~,I " 3-" t 2os-Y-OOl ~ T " ~ ' ~ ~nst~,s,'R L, GR$rouI I~SrE ~t vl~r NITROGEN $ I L~NCER ! E L'j~ d m , m R£VERS ! t VRLVE5 EXPANSION TURB] / I ,+,-l"m"l,I +-£_,.., llllll + II I I II I I I . Ot-250! to+ m I-- I ,~" )I "~ ,, i ( 1 I HRIN VRPORIZER| I --'-- We--"-.---.--- ,q e--i ++'-~' I L IQUil .r'--I P,ux IL ! ~RY VRPgR ! Z£R I -t4 --~ -t---~+4 i d I LIGUlO OXYGEN FILTERS i .,.,~ lLmutr m /t ~,~. I I -ioomw,.rmo=:,, IPROClUCTI ('l't¢'~e-, I L.jSLLIBCOOLL~X ~ ,I C HIGH PRESSURE ;f COLUHH TURBINES 1! ! ! I I ! BOIE= lll~l'dMIIhpmOt~Mn~WltmKItE I ~i~ii¢~iilotl. it tl+,mtnot bl tnRq~I~ r ~mlx.o. ¢1===In lett earmm ~ ~.~ = ~ ~tlon It b,J -,t,.mitt=lto ~ = d t oar ~ I t M b l l a = d o a l l t l e l l l ' ~ l m d l M l t , lml I CIRI/PLI~CER BELUP.FI METH/tNOL PROJECT C00£ INLET,, RLRSKR DavyMcKee ENGINEERS AND CONSmUCTIDRS lt=4-1MI I1~I'/111 AIR ,~pI~RRTION PLRNT • . , s , , I . " ' I ..,,,9 I ' I IO . ~.. ~.. • I.! I I;,,l~,l!,,I,,,, ...,.. ~ . . . '~'111 J J 1111 . . . . . . . 1 Lt l LLL[ . .- ,I t , I -i ...... i-i (H[Ti I IO0 O013]Io.trc tlo oo i1,8o.3o E11~2*"~'*°'~_~"i,-~,-i------i ~'~nrt~L ~l~O""n" .....i E ! !.. I..,'! | .,ot~ a o l~,o'f~ I I I a o o oo ? l i..~ I s~o o o I ~ ?,I 3 ~ 1 i N|TROaENCOHPRESSOR ZNTERCOOI.ER C Y 00~ ] v~nEo.1~n~ F . Q[ /~T| OOLER N[TROOF.NCOHPRE[~;0R ~ i'iol - I 1 ~mm" i~ il m ~ m m N m . . . . W . . . . . . N I% / ~ \ y -- m ~ m ~ m m . . . . . . . . . --4 / -- wmmm -,~ j l ! --~mJ f- ,~ ..,, ~ i /~.,~i ~ ii~:iii:~"'~il¸ i • • ~ /;~ 1 ~H.~/: ~ i:,~. ~~ m ~ E IGOOL.ER U ~ R PRCKRgE N~ T o co,q/, r ~ o LOCKHO#P~R .'~ 205-Y-OOt } , ,. . * • ,r- ~L~ Nd? TO CO,qLD#Y~rR . ".: . : I)~-204-Y-OOJ.'~ : a m I II I~T~4EflT AIH II, T I I I I I! UrILIYY ! i~lra: T,k I~r~t~,~,~epmpmyd DAVY i~X r.r ¢OF.FORAi"IOLIt r ~ t mt I~ h ~ l mr mx~. • =~ b mlf mm~ r ~ ~ ! h be wbmltml ~ I~nk,.Cm. ,m,ml,',W~ wl~c,h , ~ ~ cIR I/PLACER BELUGA ,~EItlENOL PROJECT NITROGEN/PLANT AI R • SYSTEM A I R ~ r DawMcKee ENGINEERS AND CONSTRUCU'3R "cz ": -,. m NQMKNCI.ATURF. T - C " g - : TYPE I=&PAClTY BsIiR PIT AIR SEPARATION PLANT - AREA 101 • oprlIATING PRlilIURarl • T E M P I E N A * l ; a N ar M - M/ILTIKRI/%~ GIICANIIION IEYECL. 18 - IIITAINLIINII IIb'll'llL Cl - CAIn" INON D - OnIVl W - WRImHT ic~q~ - A(:CIEIIONIKI ,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 N0 . M CS" lib " ¢:1 13 W AC(: - MATER|AI. G&NBON liTIKIt L IT/tINS*KEg BTI¢KI. OAIT ImON DMtVlC WEi6HT ACeI[IIIOII| a*& 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. ~:. 0816R 716 i1| ii , , m • 4.~'~,°-O" r ~TS:o" I ---- IOI-D tOl-~ i ; ....... i I--,I.--I i ..... i i ..........! i..i 0 !.,,1 in 3 ? for-e, 111 _ ~.L.,.. REV|S|ONS I~EVlS|OHg ~ ~i" NO. DESCRIPTION_. BY CHK. DATE KD. ~I~BCR|PTIrOH | In" CHK. DATE DNG.NQ. j IA P.~e..,/M. R~'vtew .=o.K ~/~18/ o Is_~_,_='~'~eIR~,,~,~R=~Ti,~,.J "p,~.~-_: I i l I I i I d ..... lClEFFU~;S~ ~ ..,..+p.~. ...... I ~ ~ Yr'! =" ' . . . . I . I I HI rS~.O" - ----..-4m _ ~.L-- IoZ.A ~ ~. . . . ,5, _ "'%, I0'~. ;~( ,IC, IO?.iSOIA ," • ~ !-1- I02.1GOI ~-h. ,~~ i I' i' i _. _L-~i ,o~-~ _c JOZ-IGO~A " /~, /.,@. " I I I I ,3 rJ o I" 4. 0 1. F I CLIENT • CIr. PLA~'~ "- DavyMcKee ENGINEERS A N D C O N S T R U C T O R S T nl Y A I P-- .~"PA,e,~ r / O A / , PLAN'I" AIR A N D AI/7".eOG~'/V SY~T&M~ ,: !. "2- - T| TLE IAz, P I s(c*,, = I ' , 4o'. o"L ~.N|HG HO- 55.~0- I O E - P - O 0 / / loi I E I 1502 ii, .Li , , / ~ , ~ ¢ , . I~-1~oe..'I[- +.,.~,.,... ,++, I~ I I [ i,' l', '2 .,,x I :'"'4 ,,,IOl. : 1:301 • .'! "'. i +, 4 i TYPICAL - MODUt.,&'S I01D ¢, DavyMcKee I~.ZEHT CIRI "/PLACE,e g~LUGAMt~THAMQLPBOJ~CT E N G I N E E R S A N D --UOOE 1WLET,-ALASKA tr~l • 1% I0"0"1 ,, ':' • ' .~' ~ ' - - ~ '"'-~ oEs TITLE BY A I ~ S6PA~ATIOI~, PLAMT" A I ~ AMD Cl('n APp . PLAId" CONSTRUCTORS ,, i , REV. 5550-t02-P-002 DR~HIHg HO- i t I --#-.. I.-.- w I01- , . ~0'2C tot- :30tC J_J_ I :1 PIP~ RRC,~-..----..~ -I I J I "1 '.'~ .'. ', . .' . W -- " V -I I .... Io~.-15olA !o~. _t~i~ ~._:-I_~_~i_~ I 5 o~.A -LI-io~. T6,o~c, "1 I_ t i t¢ Xoq.. 1~o2¢. to'l.l:lotC I~9.. I~o2A-1.J i I I loq..t5 o15__ .to2, 1302~ I I I I Io2.25o1 I I %0 "L.IG=o I 5--1-~. II • t| ~IEXT • C~m+/PLAC+~ " BF:EUGA /46TI~AIVOLP£oJ~cT • CO0~ llVL~T, ,ALASZA I i"IILE CK'DI A I F~ 5£-'PA,~A TIO/J, P L A I t T A/~P. AtL/D MITaO~M ~Y'3T£M5 PLAM DavyMcKee ENG~IEERS AND CONSTRUCTORS SCALE t aw | O I T ORAN|KS MO- ' 5 5BO-IO2-P-005 i REY. 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 C 1058R 8/2 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. 1058R The raw gas leaves the gasifier and enters the 8/3 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, C 1058R 8/4 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 'i 'i "£ : 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. 1058R 8/5 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. (i 1058R 8/6 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. 1058R All 8/7 L. 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 C 1058R 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 8/8 ,! %.! • P Lr 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. ]058R 8/g 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. 1058R 8/10