Process Overview

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Process Overview
COAL GASIFICATION The ConocoPhillips oxygen-blown coal gasification technology features a slurry-fed, two-stage gasifier, a slagging first stage and an entrained flow second stage. The gasifer is a refractory-lined vessel, which produces raw synthesis gas and an inert, vitreous slag containing the mineral content of the feedstock. The slag may be used for various construction applications. Syngas produced is about 1900 F, contains entrained solids from the second stage and is cooled in a fire-tube boiler to produce saturated high-pressure steam. GAS CLEANUP The raw syngas exiting the syngas cooler is filtered to remove the unreacted entrained solids, which are recycled to the gasifier. The filtered "sour" gas consists mainly of Hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2), water (H2O), and smaller quantities of Nitrogen (N2), methane (CH4), hydrogen sulfide (H2S), and carbonyl sulfide (COS). The sour gas is cooled further to about 100 F. The cooling is accomplished within several heat exchangers. Water condenses from the gas as it is cooled, generating a condensate containing ammonia (NH3), some of the H2S and CO2, which is sent to water treatment. ACID GAS REMOVAL The cooled sour gas enters an acid gas removal system (AGR) based on methyldiethanolamine solvent, which removes the H2S and a portion of the CO2 contained in the gas. Once cleaned of the H2S, the gas is ready for use as a fuel gas for the gas turbine in the power block. In addition, an acid gas stream is produced which is directed to a sulfur recovery unit. SULFUR RECOVERY In a series of catalytic stages, a Claus sulfur recovery unit converts H2S to elemental sulfur, which is greater than 99.99% pure. The sulfur is sold for agricultural applications. WATER TREATMENT & RECYCLE In the water treatment system, dissolved gaseous contaminents are removed by steam stripping. The stripped gas is integrated into the gasification process while a major portion of the stripped water is recycled to the slurry preparation area and the remainder to the outfall. POWER BLOCK Key elements of the combined cycle power block are an advanced gas turbine generator, a heat recovery steam generator (HRSG), and a steam turbine. The gas turbine is fired with clean syngas from the gasification block, with its exhaust gas directed to the HRSG. The steam generated in the HRSG is combined with HP steam from the gasification block, superheated and sent to the steam turbine. The net power produced is the combined generation from the gas turbine and steam turbine minus the auxiliary requirements for the air separation unit, gasification block, and power block. AIR SEPARATION UNIT A conventional air separation unit provides 95% pure oxygen for the gasifier operation.

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