COAL GASIFICATION: AN ALTERNATE SOURCE OF ENERGY

This study offers an alternative to the energy crisis dilemma: coal gasification. It aims at (1) developing a conceptual design for the production of synthetic gas using an optimized process configuration based upon the Koppers-Totzek gasifier, (2) advancing the concept to commercial scale employing the process configuration as developed, and (3) modifying as required and extending the conceptual design by adding needed process units for converting the synthetic gas produced to industrial fuels and chemical feedstocks.; To achieve those goals, the study is systematically divided into four parts:; (1) The first consists of an introduction exploring the concept of coal gasification vis-a-vis coal processing as illustrated in four possible routes: pyrolysis, solvation, hydrogenation, and synthesis gas. It declares the purpose and logic behind the different choices that are made. Ten different processes for coal gasification are reviewed in Chapter 2 and categorized according to the heating value of the gas produced.; (2) The next two chapters provide specific information required to carry on this study. Chapter 3 describes in detail the process design of the coal gasification unit and related facilities including coal receipt and preparation, air separation, acid gas removal, sulfur recovery, sour water stripping, and ash-water/slag handling. The bases of design are stated in Chapter 4.; (3) Chapter 5 evaluates the economics of the coal gasification plant by investigating investment costs, operating costs, profitability, sensitivity of product gas cost to crucial plant parameters, and the viability of the Koppers-Totzek process as compared to other competing processes. The results show the Koppers-Totzek coal gasification as an economically flexible and widely competitive process.; (4) The final chapter addresses the applications of synthetic gas as the demand grows for an alternative energy source. Two applications are considered: industrial fuel and chemical feedstocks. The facilities for cogeneration are explored and designed to convert the medium-BTU gas into electric power for plant and residential use and steam for heavy oil recovery. Methanol synthesis and the production of chemical feedstocks and gasoline complete this chapter on coal gasification applications.