Showing papers on "Pilot plant published in 1976"

Mathematical modeling and optimization of the dehydrogenation of ethylbenzene to form styrene

Abstract: A mathematical model is developed for a styrene pilot plant reactor. The steady state version of this model was used to optimize the location of a steam injection port part way along the catalytic bed. Significant improvement in reactor performance was predicted by splitting the steam feed between the reactor inlet and the injection port. Performance was measured in terms of market value of products minus a utility cost for the steam. Studies were also carried out via computer simulation to determine optimal operating conditions. An important result was the relationship of optimal steam-to-ethylbenzene feed ratio to the kinetic parameters which describe the main dehydrogenation reaction. A pilot plant was constructed and operated in order to investigate experimentally the predictions of the mathematical model. Instrumentation was designed and installed so that an on-line digital computer could acquire process measurements directly and establish operating conditions. The experimental program confirmed the improved performance by operation of the reactor with a steam injection port and the existence of an optimum of the steam-to-ethylbenzene feed ratio as indicated by simulation.

Purification of Wastewater from Coking and Coal Gasification Plants Using Activated Carbon

Abstract: Activated carbon is suitable for the removal from wastewater of organic compounds, resistant to biological treatment, with regeneration of the saturated carbon. The design of a purification plant depends on the concentration and the kind of dissolved substances and on the desired degree of purification. Different types of activated carbon have been used to establish adsorption isotherms of the water to be cleaned. The wastewater is passed through a fixed bed of carbon showing the highest adsorption capacity, and the speed of displacement of the mass-transfer zone and its extent are determined. In this way the size of the adsorption vessel and the amount of carbon to be discharged into the regeneration unit can be calculated. The saturated carbon is regenerated in a fluidized bed operated by hot steam. The desorption of compounds reversibly adsorbed on the carbon and the decomposition by steam of substances irreversibly adsorbed have been studied under fluidized-bed conditions. In pilot plant test...

Coal processing: the Exxon donor solvent process

Abstract: The development of the Exxon coal liquefaction process over 10 years is described. Exxon is using lower temperatures and lower pressures (approximately 100 bar) than were used in the Bergius process. The donor solvent is produced in a separate, fixed bed, catalytic hydrogenation step. Early research was broad in scope including, both hydrogenated and unhydrogenated recycle solvent studies. Alternate solids/liquids separation studies were tested (vacuum distillation was chosen). Work progressed with a pilot plant converting 1 ton/day, detailed solvent characterization, solvent hydrogenation research, and product characterization and possible product variations. Products are naphtha and fuel oil with some choice of proportions of each. Efficiency of the process is about 50 percent using the method of calculation given. Now, a 250 ton/day pilot plant is being designed. The 250-ton/day pilot plant size would allow us to establish commercial-scale equipment reliability and design criteria, to obtain engineering data for confident scaleup, to confirm process performance on a larger scale, and to establish key operability constraints. Engineering scaleup data are required particularly in those parts of the coal liquefaction plant that involve multiphase operation with coal-derived slurries. In this category, we can list slurry pumping and heating, slurry furnace operation, liquefaction reactor engineering,more » slurry fractionation, and handling of liquefaction residue. (LTN)« less

The PUROX System

Abstract: Union Carbide's PUROX System employs a partial oxidation process using oxygen for convert­ ing solid waste to fuel gas and inert slag This sys­ tem has been developed over the last several years After initial studies, a S-ton/day pilot plant was built and operated under a variety of conditions to develop the basic process The process has now been successfully demonstrated on a commercial scale in a 200 ton/day facility at Union Carbide's plant at South Charleston, West Virginia The operation at South Charleston is continuing with the objective of obtaining additional design in­ formation Figure I gives a brief overview of the input and output from the process One ton of refuse re­ quires about 02 ton of oxygen and produces 07 ton of medium Btu fuel gas, 022 ton· of sterile residue and 028 ton of wastewater Within the process 003 ton of oil is separated in the gas clean­ ing train and recycled to the furnace for cracking into additional gas All of these numbers are ap­ proximate and are given in an effort to give you a simplified view of the overall process Figure 2 shows a schematic of the reactor with an indication of the types of functions that are re­ quired for a successful plant operation The key element of the system is a vertical shaft furnace Refuse, which has been preprocessed for recovery of materials such as iron, is fed to the top of the furnace through a gas seal to prevent escape of fuel gas Oxygen is injected into the bottom hearth section to provide the partial oxidation that drives the reactor The furnace is maintained essentially

Slagging fixed-bed gasification at the Grand Forks Energy Research Center

Abstract: The recent high level of interest in slagging fixed-bed gasification, as evidenced by the studies at Westfield, Scotland, and the selection by ERDA of this process for a demonstration plant, indicates that this may be the process of choice for second generation gasifiers. This brief summary has been prepared to describe pilot plant facilities and capabilities of the only existing slagging fixed bed gasification pilot plant in the United States. In addition the objectives of the slagging gasification research program which was reestablished in 1974 at the Grand Forks Energy Research Center of ERDA are presented. The slagging gasification pilot plant was first designed and operated under the Bureau of Mines, Dept. of Interior, during the period 1958 to 1965 to determine the feasibility of slagging operation and to assess operational parameters. From 1965 until 1974 the pilot plant was essentially maintained in a moth-ball status. Operation of the GFERC gasifier was resumed in May of 1976 after reconditioning the unit and installing a new oxygen supply system. To date, the resumed operations have been primarily directed at training operating personnel, developing sampling and analytical procedures, and establishing reproducibility in operating data.

Status of the steam-iron program

Abstract: Construction of the pilot plant began in September 1975; mechanical completion was achieved in July 1976. Erection of the reactors and of the steel deckwork around them was completed in March 1976. During the latter stages of plant construction, efforts were concentrated on commissioning of the peripheral systems. The slurry vaporizer has been tested, and although tests of longer duration will be necessary and more concentrated slurries will have to be vaporized, it is believed that the principle of high-pressure slurry vaporization was demonstrated. The internal refractory lining has been cured. Several support programs are underway. The kinetic studies program is to develop improved iron solids for use in the steam-iron process. Sixty-seven attrition tests and 56 reactivity tests have been made on a variety of catalysts and support materials. Twenty-six tests were conducted with a Western Kentucky bituminous coal char.

High-level waste vitrification by spray calcination/in-can melting

Abstract: Federal regulations require that high-level liquid waste (HLLW) be converted to a solid for custody in a Federal repository. The Spray Solidification/In-Can Melting process has been developed and is being demonstrated for commercial application. The bases used are similar to those of the NFS plant and to anticipated regulations for waste canister receipt at a Federal repository. The reference NFS flowsheet combines plant HA Column Wastes, Low-Level Wastes, and various HLLW process recycle streams to produce a borosilicate glass. After the canister is filled and sealed, the lid weld will be inspected and decontaminated. Equipment and instrumentation for feed supply to the calciner, calcination, melting, welding, weld inspection, canister decontamination, and in-cell canister storage are being designed and demonstrated. Preliminary facility layouts, equipment design data, and instrumentation needs are provided for major process equipment systems. Additional demonstration work is being performed to verify and complete the plant scale equipment design, including full-scale nonradioactive equipment testing, nonradioactive facility mockup for equipment remote operation and maintenance demonstration, and pilot plant production of waste glass from commercial fuel HLLW. The technology for spray calcination and in-can melting is ready for commercial application. Required additional work is described. A preliminary evaluation is made ofmore » materials that may be released from the process from normal and abnormal operations in the facility. 34 figures, 20 tables. (DLC)« less

Biological oxidation process control

Abstract: Water to be analysed is fed to reaction zone, and nutrient medium added, opt. simultaneously O2 is fed to reactor in controlled quantities, pref at constant pressure, as biological oxidation proceeds, and gas evolved from liquid drawn off, contg.unconsumed O2 and CO2 produced. The gas stream is passed to the CO2 absorbent system and recycled to reactor. The quantity of O2 used is measured by water gauge system etc. The movement of levels being proportional to O2 used and CO2 removed. Small samples of reaction medium are drawn off at predetermined intervals to allow analysis of compsn. Used for kinetic determination of BOD or COD of waste water, opt. forming pilot plant to enable design of industrial scale units.Automatic monitoring of Ph and O2 content of liquid etc. may be used

High Btu gas from coal: status and prospects

Abstract: A generalized process scheme for making substitute natural gas (SNG) from coal is presented in the form of a flowsheet. The Lurgi, Koppers-Totzrk, and Winkler processes are described on a commercial scale. The Hygas, Carbon Dioxide Acceptor, Synthane, Bi-gas, and Agglomerated Ash processes are described on a pilot plant scale. Diagrams of the gasifiers for all the processes are included. (EJH)

Pilot plant for production of fish ensilage and the economics of production

Abstract: This communication describes the design aspect and functions of individual pieces of equipment of a pilot plant for the production of fish ensilage based on lactic acid fermentation process. Details about the equipment, process flow sheet and equipment layout of the pilot plant have been given. An attempt has been made to prepare an estimate of the cost of production of liquid ensilage and solid feed mix.

Coming - Solar power plants

Abstract: According to Sandia Laboratories, technical manager for ERDA's solar central-receiver power project, the U.S. should have a 10-MW pilot solar electric power plant by 1980. Other milestones in the program, which began in 1975, include operation of a 5-MWth solar test facility in 1977, and the first commercial demonstration plant by 1985. The solar central-receiver concept incorporates a field of individually guided and controlled mirrors, called heliostats, which offer a 2-degree-of-freedom focusing system. Simulating a very large, steerable Fresnel reflector, the heliostat field redirects the Sun's energy to a tower-mounted receiver, which absorbs the radiant energy in a circirculating fluid for direct powering of a steam-turbine/generator or for storage. The system designs proposed for the pilot plant appear workable, requiring no technological breakthroughs. However, major cost reductions are warranted before the concept is economically competitive.

Pilot plant operation of a nonadiabatic methanation reactor. [15 refs. ; Raney nickel catalyst]

Abstract: The design and operation of a pilot plant scale hybrid methanation reactor is discussed The hybrid methanator, utilizing a finned, Raney nickel coated insert, consolidates features of the tube-wall and hot-gas-recycle methanation reactors Data are presented from four tests lasting from 3/sup 1///sub 2/ weeks to three months Topics discussed include conversion, product yields, catalyst properties, and reactor temperature profiles A one-dimensional mathematical model capable of explaining reactor performance trends is employed

Biological Pilot Plant Study at Radford Army Ammunition Plant

Abstract: : Biological pilot plant studies were conducted at Radford Army Ammunition Plant (RAAP) on wastewaters originating from the manufacturing of single-base propellants and nitroglycerine. These wastes were treated with a complete mix activated sludge system, a rotating biological disc treatment system, and an aerated waste stabilization (dispersed growth) system. Extensive studies indicated that the complete mix activated sludge system tested was unstable on a long-term basis, unless very close control was maintained over waste composition and loading rates on a continuous basis, conditions not possible to meet at RAAP. The rotating biological disc treatment system was evaluated for a period of over three months and found to be very stable and to provide excellent treatment. A short study conducted using the aerated waste stabilization (dispersed growth) system indicated this to be a highly efficient waste treatment system.

Effect of coal minerals on reaction rates during coal liquefaction. [12 refs]

Abstract: The effect of coal minerals in promoting reaction rates during coal liquefaction are studied Ten different coal minerals as well as coal ash and actual SRC residue from the Wilsonville pilot plant have been individually screened to rate their catalytic activity on hydrogenation and hydrodesulfurization of creosote oil relative to that of a commercial Co-Mo-Al catalyst In addition the effect of recycling mineral matter from successive batch autoclave runs is also studied The results show conclusively that certain coal derived minerals increase both hydrogenation and hydrodesulfurization activity during coal liquefaction, with iron compounds being second to the Co-Mo-Al in increasing reaction activity Most interesting is that filter cake residue from the Wilsonville pilot plant proved to be one of the more active catalytic agents Also, the physical state (particle size) and agitation as well as chemical composition of mineral matter are shown to influence significantly its effect on reaction rates In support of the screening results, moreover, continued recycle of mineral matter residue is shown to lead to increased reaction rates

Magnetic separation of solids from liquified coal

Abstract: High gradient magnetic separation (HGMS) has been applied to the removal of ash-forming mineral matter and sulfur in the form of pyrites from solvent refined coal. These materials occur as suspended solids which are very finely divided in the product of a liquifaction pilot plant. The pyrites contain part of the total sulfur found in the coal. The rest is bound organically in the coal structure. Actual pilot plant process conditions are simulated in a continuous-flow high-pressure system which feeds the liquified coal at 500°F to a ferromagnetic matrix centered in the bore of a Bitter solenoid. Field values of up to 100 kOe have been used although lower fields would be dictated if conventional magnets are to be used commercially. Results indicate that the removal of ash and inorganic sulfur increase with magnetic field and decrease with flow rate. Typical results are shown in Fig. 1 where the percentage reduction in sulfur in the filtrate is plotted against H/v. H is the applied magnetic field in kOe and v is the flow velocity in cm/ min. This parameter is derived from the ratio of magnetic force to the viscous drag force of the carrier fluid. Data for use in pilot plant design have been collected.