EPA-650/2-74-009-k

September 1975
Environmental  Protection Technology Series
    EVALUATION  OF  POLLUTION  CONTROL
               IN  FOSSIL FUEL  CONVERSION
                                    PROCESSES
            COAL TREATMENT:  SECTION 1.  MEYERS PROCESS
                                U.S. Environmental Protection Agency
                                 Office of Research and Development
                                      Washington, D.C.2046D

-------
                                      EPA-650/2-74-
EYALUATION  OF  POLLUTION  CONTROL
      IN FOSSIL  FUEL  CONVERSION
                  PROCESSES
     COAL TREATMENT:  SECTION  1.  MEYERS PROCESS
                         by

                      E.M. Magee

            Exxon Research and Engineering Company
                      P.O. Box 8
                 Linden , New Jersey 07036
                  Contract No. 68-02-0629
                   ROAP No. 21ADD-023
                 Program Element No. 1AB013
             EPA Project Officer: William J. Rhodes

           Industrial Environmental Research Laboratory
            Office of Energy , Minerals, and Industry
           Research Triangle Park, North Carolina 27711
                      Prepared for

           U.S. ENVIRONMENTAL PROTECTION AGENCY
              Office of Research and Development
                  Washington, D. C. 20460

                     September 1975

-------
                       EPA REVIEW NOTICE
 This report has been reviewed by the  U.S. Environmental Protection
 Agency and approved for publication.  Approval does not signify that
 the contents necessarily reflect the views and policies of the Environ-
 mental Protection Agency, nor does mention of trade names or commer-
 cial products constitute endorsement or recommendation for use
                  RESEARCH REPORTING SERIES

 Research reports of the Office of Research and Development, U.S. Environ-
 mental Protection Agency, have been grouped into s'eries.  These broad
 categories were established to facilitate- further development and applica-
 tion of environmental technology.  Elimination of traditional grouping was
 consciously planned to foster technology transfer and maximum interface
 in related fields.  These series are:

           1.  ENVIRONMENTAL HEALTH EFFECTS RESEARCH

           2.  ENVIRONMENTAL PROTECTION TECHNOLOGY
           3.  ECOLOGICAL RESEARCH
           4.  ENVIRONMENTAL MONITORING

           5.  SOCIOECONOMIC ENVIRONMENTAL STUDIES
           6.  SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
           9.  MISCELLANEOUS

This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series.  This series describes research performed to
develop and demonstrate instrumentation, equipment and methodology
to repair or prevent environmental degradation from point and non-
point sources of pollution.  This work provides the new or improved
technology required for the control and treatment of pollution sources
to meet environmental quality standards.
This document is available to the public for sale through the National
iechmcal Information Service, Springfield, Virginia 22161.


                 Publication No. EPA-650/2-74-009-k
                               11

-------
                            TABLE  OF  CONTENTS
 1.   SUMMARY	       1

 2.   INTRODUCTION	  .	       2

 3.   PROCESS  DESCRIPTION	       4
     3.1   Reaction Section	       4
     3.2   Sulfur Removal  Section	       8
     3.3   Product  Drying  Section	       8
     3.4   Sulfur Recovery Section  	       8
     3.5   Iron Sulfate Recovery  Section 	       8

 4.   MODIFIED PROCESS DESIGN  INCLUDING UTILITIES  AND EFFLUENTS.  .  .       9

     4.1   Major Design Modifications	       9

     4.2   Effluents to Air	       9
          4.2.1  Coal Storage and Preparation	       9
          4.2.2  Reaction Section 	       9
          4.2.3  Sulfur Removal Section 	      16
          4.2.4  Product Drying Section 	      16
          4.2.5  Iron Sulfate Recovery Section	      16
          4.2.6  Sulfur Recovery Section	      16
          4.2.7  Auxiliary Facilities 	      17
          4.2.8  Minor Vents	      18
     4.3  Liquid and Solid Effluents	      18
          4.3.1  Coal Storage and Preparation	      18
          4.3.2  Reaction and Sulfur Removal Sections 	      18
          4.3.3  Product Drying Section 	      18
          4.3.4  Iron Sulfate Recovery Section	      19
          4.3.5  Sulfur Recovery Section	      19
          4.3.6  Auxiliary Facilities 	      19

 5.   THERMAL EFFICIENCY 	      20

 6.   SULFUR BALANCE	      22

 7.   TRACE ELEMENTS	      24

 8.   PROCESS ALTERNATIVES AND IMPROVEMENTS	      28

 9.   PROCESS DETAILS	      33

10.   TECHNOLOGY NEEDS 	      36

11.   QUALIFICATIONS	      38

12.   BIBLIOGRAPHY .	      39
                                   iii

-------
                             LIST OF TABLES


No.                                                                   Page

 1        Stream Identification, Original Design	     6

 2        Stream Identification for Modificed Process 	    11

 3        Feed Coal Analysis (Dry Basis)	    15

 4        Thermal Efficiency	    21

 5        Sulfur Balance	    23

 6        Minor and Trace Elements In Coal Feed (Lower Kittanning)
          and Product Coal (from EPA)	    25

 7        Trace Element Analysis Fox Mine Lower Kittanning Seam,
          Clarion County,  Pennsylvania (From Ref.  9)	    27

 8        Material Balance for Removal of Dissolved Solids
          and Iron From Meyers Process.  „	    30

 9        Process Alternatives and Improvements 	  ...    32

10        Power and Steam Balance	    34

11        Water Balance	    35
                                  iv

-------
                            LIST OF FIGURES
1        Original Basic Design of Meyers Process .........       5




2        Flow Diagram - Modified Meyers' Process .........      10




3        Flow Plan for Removal of Dissolved Solids
         and Iron from Meyers Process
                                                                      28

-------
                         TABLE OF CONVERSION UNITS
  To Convert From


 Btu


 Btu/pound


 Cubic feet/day


• Feet


 Gallons/minute


 Inches


 Pounds


 Pounds/Btu


 Pounds/hour


 Pounds/square  inch


 Tons


Tons/day
             To
 Calories,  kg


 Calories,  kg/kilogram


 Cubic meters/day


Meters


 Cubic meters/minute


 Centimeters


 Kilograms


 Kilograms/calorie8kg


Kilograms/hour


Kilograms/square centimeter


Metric tons


Metric tons/day
Multiply By


  0.25198


  0.55552


  0.028317


  0,313480


  0.0037854
   »

  2.5400


  0.45359


  1.8001


  0-45359


  0.070307


  0.90719


  0.90719
                                 vi

-------
                                1.  SUMMARY
          The Meyers process being developed by TRW, Inc. has been reviewed
from the standpoint of its potential for affecting the environment.  The
quantities of solid, liquid and gaseous effluents have been estimated,
where possible, as well as the thermal efficiency of the process.  For the
purpose of reduced environmental impact, a number of possible process modifi-
cations or alternatives, which could facilitate pollution control or increase
thermal efficiency, have been proposed; and new technology needs have been
pointed out.

-------
                                     - 2 -
                             2.  INTRODUCTION


           Along with improved control of air and water pollution, the
 country is faced with urgent needs for energy sources.  To improve the
 energy situation, intensive efforts are under way to upgrade coal  the
 most plentiful domestic fuel, to liquid and gaseous fuels which give
 less pollution.  Other processes are intended to convert liquid fuels to
 gas.  A few of the coal gasification processes are already commercially
 proven, and several others are being developed in large pilot plants.  These
 programs are extensive and will cost millions of dollars, but this is
 warranted by the projected high cost for commercial gasification plants
 and the wide application expected in order to meet national needs.  Coal
 conversion is faced with potential pollution problems that are common to
 coal-burning electric utility power plants in addition to pollution pro-
 blems peculiar to the conversion process.   It is thus important to examine
 alternative conversion processes from the  standpoint of pollution and
 thermal efficiencies and these should be compared with direct coal utili-
 zation when applicable.   This  type of examination is needed well before
 plans are  initiated for  commercial applications.   Therefore,  the Environ-
 mental Protection Agency arranged  for such a study to be  made by Exxon*
 Research and  Engineering Company under contract  EPA-68-02-0629,  using all
 available  non°proprietary information.

           The  present study under  the contract  involves preliminary  design
 work to assume  that  conversion processes are free from pollution where  pol-
 lution abatement  techniques are  available,  to determine the overall  efficiency
 of  the  processes  and  to  point  out  areas where present  technology and  infor-
 mation are  not  available  to assure  that  the  processes  are  non-polluting.

          All significant  input  streams  to  the processes must  be defined
 as  well as  all  effluents and their  compositions.   This requires  complete'
 mass and energy balances  to define  all gas,  liquid,  and solid  streams.
 With this information, facilities  for control of  pollution  can be  examined
 and modified as required  to meet Environmental Protection Agency objectives
 Thermal efficiency is also  calculated, since it indicates  the amount  of
 waste heat  that must  be rejected to ambient air and water and  is related  to
 the total pollution caused  by the production of a  given quantity of clean
 fuel.  Alternatively, it is a way of estimating the amount  of raw  fael
 resources that are consumed in making the relatively pollution-free fuel
At  this time of energy shortage this is an important consideration.
 Suggestions are included concerning technology gaps that exist for techniques
 to control pollution or conserve energy.  Maximum use was made of  the lit-
 erature and information available from developers.  Visits with some of the
developers were made, when  it appeared warranted, to develop and update
published information.  Not included in this study are such areas as cost
economics,  operability,  etc.  Coal mining and general offsite facilities
are not within the scope of this study.
   Prior to June 1,  1974 Exxon Research and Engineering Company conducted
   business under the name Esso Research and Engineering Company.

-------
                                   - 3 -
          Our previous studies in this program to examine environmental
aspects of fossil fuel conversion processes covered various methods
for coal conversion to clean fuels.  Reports have been issued on both gasi-
fication and liquefaction processes including Koppers-Totzek, Synthane,
Lurgi, C02 Acceptor, COED, SRC and BI-GAS processes (1,2,3,4,5,6,7).  The
present report extends these studies to include chemical cleaning of coal by
the Meyers process being developed by TRW, Inc. under contract to EPA.  In
this process pyritic sulfur is removed from coal by the action of a solution
of ferric sulfate.  The coal is not "converted," and it essentially retains
its original heating value.  The pyritic sulfur leaves the process as elemental
sulfur and iron sulfates.


          We wish to acknowledge the information and assistance provided
by the Environmental Protection Agency.  This study, is based, to a
large extent, on information supplied by EPA and on reports published
by TRW, Inc. for EPA.

-------
                                    - 4 -
                         3.  PROCESS DESCRIPTION
          In the Meyers  process, the pyrites in the coal are removed
by reaction with ferric sulfate  in a solution containing ferric and
ferrous sulfates and sulfuric acid.  The ferric ion is continuously
regenerated by reaction of oxygen and ferrous ion.  The elemental
sulfur product is extracted with an organic solvent.  The iron product
from the pyrites is removed as solid ferric and ferrous sulfates.

          A block flow diagram of the basic Meyers  process is shown  in
Figure 1.  The contents of the indicated streams are shown in Table 1=
This diagram and description are based on information supplied by EPA
(in the form of a process flow sheet produced by Dow Chemical U.S.A.).
and EPA reports  (8,9).  Later evaluations of  the process may be
available but for the present study no improvement would be expected
in the results without pilot unit data.  The  process description  is not
complete without utilities, coal preparation  and storage, etc.  These
items will be addressed later in this report.

          A more recent design for a commercial plant has been completed
by Dow Chemical U.S. A. (12)  That design has a more conservative approach
to heat integration than the one used in the present work, produces a
drier, compacted product and shows electricity to be purchased.

3d  Reactor Section

          Coal that has been ground to less than 100 mesh (Str. 2) is
mixed with recycled leach solution (Strs. 8, 11, 13) in a flow through
mixing tank.   The mixing vessel  is maintained at about 210°F.   The
slurry is continually pumped from the mixing vessel to one of 10 reactor
vessels.

          In the reactor vessels, the slurry is contacted with oxygen
at ©bout 300°F.   The pyritic   sulfur is 95% converted to elemental
sulfur and sulfate in the reactor vessels.  The reactions taking place in
the reactors are shown below:

          Leaching Reactions

          (1)  FeS2 + Fe2(S04)3  - *>  3FeS04  +  2S

          (2)  FeS2 + 7Fe2(S04)3 + 8H20 - £>  15FeS04 +  8H2S04

Since the net 304:8 production from FeS2  is approximately 1.5:1,  the
overall leaching reaction is:

          (3)  FeS2 + 4.6 Fe2(S04>3 + 4.8 H20 — J> 10.2 FeS04 + 4.8 H2S04 + 0.8  S

          Regeneration Reaction
           (4)   9.6  FeS04 + 4.8 H2S04 + 2.4  02 — J> 4.8  Fe2(S04)3 + 4.8

           Net  Overall  Reaction
           (5)   FeS2 -1-2.4  02 — $>  0.2  Fe2(S04)3  + 0.6  FeS04  + 0.8 S

-------
 Oxygen
 Feed Coal
Iron Sulfate
   Product
                        Vent
A
Reaction
 Section
                     Iron Sulfate
                   Recovery Section
                                                                            Vent
                                        Recycle Leach Sol.
         Coal and Leach
           Solution
                                              Leach Sol.
                                          Recycle  Leach  Sol
                                                  Water
                                                Water
                                                                   Sulfur Removal
                                                                       Section
                                                                   Rich
                                                                   Sulfur
                                                                   Solvent
                                                                                          Wet Coal
                                                                                                Solvent
                                                                                                and Water
                                                                               Leach  Sulfur
                                                                                  Solvent
                                   Sulfur Recovery
                                       Section
                                                       Product Sulfur
                                                                                             Solvent
                                                                               Product Drying
                                                                                   Section
Product Coal
                                                                                                                  i
                                                                                                                  Ul
                                                                                                                  I
                                                                figure 1

                                                Original Basic Design of Meyers Process

-------
                                               Table  1

Stream 2
Coal* 188, 000
FeS2 12,000
S
FeS04
Fe2(S04)3
H2S04
H2o 20,000
Solvent
°2
Inert
Stream Identification, Original Design, Ib/hr
3 4 56789
188,000 187,800 187,800
600 600 600
2,400
30,000 18,000
122,800 200 200 73,800
6,800 4,000
662,800 47,000 3V, 600 660 466,400 200
9,400 . 200
7,296
40 40

10 11



1,000
31,600
2,200
9,400 126,600
9,400


Total       220,000   1,013,400   245,000   226,200   7,336   700   562,200   400    18,800    161,400
*  Feed coal ex pyrites and moisture,

-------
Total
                                      Table  1  (Cont'd)




                        Stream Identification,  Original  Design.  Ib/hr
                                            15
                                          16
17
                                                                       18
                                                                    19
                        20
stream
Coal
S
FeSO,

H2S°4
HO
2
Solvent
°2
Inert
L£. i.-»
200

9,600 2,400
39,600 9,800
2, 200 600
231,000 50,400



200
2,400 2,400
2,400 8,600
9,800 7,400

65,400 137,800 104,400 8,400
255,800 256,000 20°


282,000   63,200   336,400   393,800   104,400   2,400   16,200   8,400
                                                                                      200

-------
                                  - 8 -
          The excess ferric and ferrous sulfates must be removed from the
system.  The slurry is cooled by heat exchange with fresh feed and then
by cooling water and is pumped to the Sulfur Removal Section (Str. 3).

3.2  Sulfur Removal Section

          In the Sulfur Removal Section, approximately 6070 of the leach
solution is removed in hydroclones and recycled to the Reaction Section
(Str. 8).  The remaining leach solution  is removed by filtration and is
passed to the Iron Sulfate Recovery Section (Str. 12).

          The wet filter cake is washed with water and then mixed with
recycle solvent (e.g., light naphtha) at 160°F and most of the elemental
sulfur is dissolved.  The resulting slurry is filtered to remove the
cleaned coal which passes to the Product Drying Section (Str. 4).  The
sulfur-rich solvent is separated from water by decantation and passes to
the sulfur recovery section (Str. 14).

3.3  Product Drying Section

          The treated coal, containing about 257, moisture and 57» solvent
(dry basis), is conducted to the drying section  (Str. 4).  The coal  is
partially dried under vacuum; the sensible heat of the coal  is sufficient
to remove all the solvent and about 2070 of the water.  The vapors are returned
to the Sulfur Removal Section (Str. 10) where they are condensed in a
water cooled vessel.  The water and solvent are separated by decantation
and reused in the process.  The coal product, containing 207» moisture
(dry basis) then leaves the process (Str. 5).

3.4'  Sulfur Recovery Section

          The sulfur-laden solvent and miscellaneous solvent and water
streams are passed to the Sulfur Recovery Section  (Str. 14).  The solvent
is removed from the sulfur by distillation and  the sulfur leaves the  pro-
cess (Str. 17).  Water and rich solvent are separated by decantation.   The
water is recycled to the Reaction Section (Str.  13) and the  solvent  is
returned to tha Sulfur Removal Section  (Str. 15).  Makeup water and  solvent
(Strs. 19 and 20) are added to the system through  the Sulfur Recovery Section.

3.5  Iron Sulfate Recovery Section

          The water filtrate from filtration in  the Sulfur Removal Section
passes to the Iron Sulfate Recovery Section  (Str.  12).  Since the process
produces iron from the pyrites, it is necessary  to remove iron from  the
system.  The filtrate is heated to about 265°FS and some of  the water is
flashed overhead.  Part of the steam  thus formed  is returned to the
Reaction Section (in Str. 11) and part passes to  the  Sulfur  Recovery  Section
in stream 16.  The remaining slurry of  iron sulfates  is filtered at  215°F
to produce an iron sulfate filter cake  for disposal.  The filtrate is returned
to the Reaction Section.

-------
                                - 9 -
                  4.  MODIFIED PROCESS DESIGN INCLUDING
                         UTILITIES AND EFFLUENTS	


          To more carefully assess the pollution potential and the thermal
efficiency of the Meyers  Process, an oxygen plant, coal preparation and
storage and utilities have been included in the design and other slight
changes have been made.  The complete block diagram for the plant is shown
in Figure 2 and the streams are identified in Table 2.  An asterisk (*)
indicates streams released to the environment.

4.1  Major Design Modifications

          The plant has been made self sufficient with regard to all
utilities.  Steam and power are generated internally, water treatment
facilities have been included, a cooling tower has been added to allow
recycling the cooling water, the coal storage and preparation section
was added and an oxygen plant has been assumed.

          The coal  analysis assumed  in the present study  is given in
Table 3.  This analysis corresponds  to that of the Lower Kittanning coal
given on page 10 of reference 8 except the pyritic sulfur content has
been assumed to be 3.21% (dry basis)  instead of 3.58%  and  the moisture
has been assumed to be  10%  to conform to previous  design  studies of the
process  (e.g., stream  1,  Table 29, p. 120 of  Ref.  8).  Reference 9,
p. 126,  gives a pyritic  sulfur content of 3.09%.   Such changes will have
little effect on the conclusions  of  this study.
4.2  Effluents to Air

     4.2.1  Coal Storage  and Preparation

          ROM coal, 8  in.  X- 0,  is received at the  plant and stored.   Three
days storage  (7920  tons,  wet) has been  suggested.  This quantity of coal
would  probably be  stored  in silos with  nitrogen  blanketing.   It would
probably be advisable  to  store more  coal  (e.g.,  30 days supply)  in a
"permanent" pile  for  emergency use.   This  pile could be covered with
asphalt  and used only  in case of  mine outage.

          The ROM  coal is conveyed to pulverizers  where the coal  is reduced
to 80% less  than 200 mesh.   (This size  is  smaller  than previous  designs
and  is  used  to enhance reaction  rates as well as to  provide a product
size suitable for  combustion).   The  coal  from the  pulverizers is  then fed
to the Reaction  Section.

           It  is  not necessary to dry the  coal as it  is subsequently
slurried in  a water solution.   It is assumed that  covered conveyers will
be used throughout to minimize  dust problems.  The coal dimunition
equipment can be  enclosed, with air vented to bag filters.   This will
reduce outside  noise as well  as  provide for dust containment.

      4.2.2   Reaction Section

           Except for minor vents, which will be discussed later,  no air
 effluents are emitted from the  reaction section.

-------
46
A
                              47
                              A
  Coal  Storage and
Preparation Section
Note:  Heavy dashed lines are
       effluent streams; others
       are used in plant or
       are products.
 30    31
     Oxygen
      Plant
        t
        21
Reaction
 Section
                                               Iron Sulfate
                                               Recovery Section
                                           32   33   34
                                                                               35
                                                                               A
  Makeup
   Water
Treatment
                                                                                         Sulfur Removal
                                                                                             Section
                                                                                              Sulfur
                                                                                            Recovery
                                                                                              Section
                                                                                                     1L
                                                                                       36  37   38    39   40
                                                                                           A
                                                                                                                Cooling
                                                                                                                " Tower
                                                                                                25
                                                                                                      26
                                                                                                                                                           Product
                                                                                                                                                           Drying
                                                                                                                                                           Section
                                                                                                                                         42    43
                                                                                                                                                        44

                                                                                                                                                        £
                                                                                                                                           Steam and
                                                                                                                                             Power
                                                                                                                                           Generation
                                                                                                                                                  29
                                                                     Figure 2

                                                       Flow Diagram - Modified Meyers Process

-------
TOTAL
                                              Table 2




                         Stream Identification for Modified Process, Lb/Hr
                                                                                               10
Stream 1 *
Coal* 188,000 188,000
FeS2 12,000 12,000
S
FeS04
H 0 20,000 20,000
Solvent
°2
Inert
188,000 187,800 187,800
602 602 602
2,438
30,060 18,°°°
122,798 200 200 73,800
6,800 4>°°°
662,800 47,000 37,600 660 466,400 200 9,400
9,400 20° 9>400
7,296
40 40
220,000   220,000   1,013,498   245,020   226,220   7,336    700    562,200   400    18,800
*  Feed coal, ex pyrites and moisture.

-------
Table 2 (Continued)
Stream
Coal
FeS2
S
FeS04
H2S°4
Solvent
°2
Inert
TOTAL
Stream Identification for Modified Process, Lb/Hr,
n 12 13 14 15 16 17 18 19 20
200 20°
2,438 2,438
1,000 9,660 2,400 2,400 8.660
31,600 38,998 9,800 9,800 7»398
2,200 2,200 600 600
126,600 231,000 50,460 65,400 137,800 104,400 18,460
255,800 256,000 20°
161,400 282,058 63,260 336,438 393,800 104,400 2,438 16,258 18,460 200

-------
                                -  13  -
                           Table 2 (Continued)
             Stream Identification for Modified Process,  Lb/Hr
21  - Air  to 0. Plant

22  - Chemicals

23  - Water

24  - Air


25  - Water


26  - Water


27  -  Product  Coal


 28 -  Air

 29 -  Water


 30 -  Water


*31 - Nitrogen


*32 -  Sludge

 33 - Boiler Feed
      Water Makeup

 34 - Cooling Water

*35 - Backwash

*36 - Air From Cooling
      Tower

*37 - Drift Loss  Water

*38 - Water Vapor
    31,520
   153,850

12,700,000
(4 X 109 scfd)

   135,560
 7,083,600


    13,234 (Dry)


   141,229

   126,000


       170


     24.050
      5,830


    129,560
 12,700,000
 (4  X 109  scfd)

     14,160

    100,000
Air to Cooling Tower
Makeup Water to Cooling
Tower at 85°F

Water plus makeup recirc.
to Cooling Tower at 105°

Product Coal to Utility
Boiler

Air  to Boiler

Boiler Feed Water  (Includes
6000 Ih/hr makeup  water)

Moisture  from Air  to Boiler
Feed Water

Vent from 02 Plant, can be
used is coal silos

From Treating Makeup Water

To  Steam  Generation
 Makeup
 Air from Cooling Tower
 Water Mist to Air

 Water Evaporated from
 Cooling Tower

-------
                                - 14 -
                           Table 2 (Continued)

            Stream Identification for Modified Process, Lb/Hr
*39 - Slowdown Water


 40 - Cooling Water


*41 - Flue Gas

 42 - Blow Down Water

 43 - Steam

*44 - Ash

 45 - Rain**


*46 - Rain Run Off**


*47 - Dust
    21,400


 7,083,600


   154,570

     6,000

   120,000

     2,541

e.g. 6" Rain in
24 Hours

e.g. 6" Rain in
24 Hours
Purge from Cooling Tower
to Holding Pond
From Utility Boiler

To Cooling Tower Makeup
Rain on Coal Storage
and Preparation Area

From Coal  Storage
and Preparation Area

From Coal  Preparation
Collect in Bag Filters
       *  These streams are emitted to the environment.
      **  Not applicable if all storage-is in silos.

-------
                            - 15 -
                            Table  3
                Feed Coal Analysis (Dry Basis)
 Proximate Analysis,  Wt.  %

Fixed carbon      53.48
Volatile matter   20.66
Ash               20.R6

Moisture = 1070 wt. dry coal
  (assumed)

Heating value
  HHV (dry) - 12140  Btu/lb
 Ultimate Analysis, Wt.
Carbon
Hydrogen
Nitrogen
Chlorine
Sulfur
Ash
Oxygen (difference)
68.53
 3.85
 1.20
 0.08
 3.92
20.86
 1.56
Sulfur Forms

Pyritic
Sulfate
Organic

-------
                                 - 16 -
     4.2.3  Sulfur Removal Section

          The only effluents  in  the Sulfur Removal Section come  from vents
which are discussed later.  Pressure filtration  is used, thus vapors are
e nclosed.

     4=2.4  Product Drying Section

          The naphtha solvent and a portion of the water are  removed  from
 the product coal by vacuum.   The resulting vapors are condensed  and returned
 to the  process system.

           The dry  product coal  heating value  has been increased  by ca  570
 (Ref.  8),  from 12,140 Btu/lb  to 12,747 Btu/lb due to ash  removal.   With added
 sulfate and  elemental sulfur  the product contains approximately  0.95% sulfur
 in the  following forms:

                   Sulfur Form
                    Pyritic
                    Elemental
                    Sulfate
                    Organic

                                         0.95%

 (This is the  analysis used in Ref. 8 but corrected for  the decrease in
 coal weight  in processing.)

          No  information  is available  on techniques  available  for  drying
 the product coal.  It  is  assumed  that  the product coal  will be burned as  is.
 Part of the coal  (13,234  Ib/hr,  dry basis) is used in  the steam  plant.
 Thus, net  product  is  175,366  Ib/hr (dry).

     4.2.5   Iron Sulfate  Recovery Section

           Except for  minor vents, there are no air effluents  from  the  iron
 sulfate section.,   The  filter  is  assumed to be enclosed  to prevent  vapors
 from escaping.   It is  also assumed that the product  iron  sulfates  will  be
 handled in a  moist form to avoid  dusting.

     4.2.6   Sulfur Recovery Section

          Again, this  section is  completely enclosed except  for  vents and
 there are  no  effluents  to the air.  If the sulfur product is  stored as  a
 liquid, there will be  no  emissions since the  storage and handling  facilities
 will be enclosed.  If  the product is handled  and stored as a  solid, then
 control of dust  is necessary.

-------
                                    - 17 -
     4.2.7  Auxiliary Facilities

          The auxiliary facilities in the complex include an oxygen plant,
raw water treatment,  cooling towers and steam and power generating
facilities.   These auxiliary units must be considered to evaluate effluent
problems and overall  thermal efficiency.

          The oxygen plant is a major consumer of power and there is a
large gaseous effluent.  It has been assumed in the present design that
an extraction turbine, using 600 psig steam, is used to drive the air com-
pressor in the oxygen plant.  The extraction steam, at 115 psig, is utilized
in the rest of the plant.  The effluent to the air consists of 24,050 Ib/hr
(5435 cu ft/min) of relatively pure nitrogen which requires no cleaning.

          Moisture containing air from  the cooling tower represents the
largest effluent to the atmosphere.  In this particular plant the cooling
water should be relatively free of volatile materials; pressures on the
heat exchangers are low and, except for the organic solvent, no volatile
organics have been reported as being present in the reaction system.  Fog
 formation can sometimes represent a problem with cooling towers.  The extent
of this problem is determined in  large  part by the plant location.  Drift
loss from the cooling  tower can cause dust problems when the solids in  the
cooling water are deposited.  It  is expected that  cooling  tower blowdown
will be sent to an evaporation  pond.  Due to the nature of the  present
process,  there should  be no noxious fumes from this pond if there are no
leaks in  the naphtha heat exchangers.

          A  raw water  treatment system  is provided to  furnish makeup water
to the  steam boiler and cooling tower.  No air effluents are expected  from
this unit.

          Product ccal is burned  in  the steam  plant and  the  flue  gas
represents  the  largest quantity of noxious  contaminants  emitted to  the
atmosphere.  The  combustion  gas contains  dust, NOX, CO and sulfur compounds
and  these must  be controlled.   The use  of product  in  the boiler furnace
also affects the  thermal  efficiency  of  the  overall plant.   Control  of
 particulate  matter can be effected by  the use  of  commercial electrostatic
 precipitators,  cyclones  and/or  scrubbers.   The use of  excess air  should
 reduce  the  CO  content of the stack gas.  NOX  emissions can be  reduced  by
 careful control  of combustion conditions and  staged firing.   The  ultimate
 limit  on NO* reductions has  not been reached  as  considerable work is  in
 progress on techniques for  NOX control.  It is expected that a  technique
 will be developed eventually for  direct removal  of WO^ from stack gases or
 for  its conversion to W2a   Thls problem,  however,  could exist  for a long
 time.

           Sulfur in the flue gas  represents a problem.  The sulfur in the
 product coal produces 1.49  Ib of S02 per million Btu.   This is  higher than
 the present Federal  limit of 1.2  Ib  S02/MM Btu for large power plants.   The
 major  part of this sulfur in the fuel is in the  form of organic sulfur
 (0.717. out of Oo95%) which is not resaoved in the process.   In many coals,
 the organic sulfur content (and total sulfur in the product coal) is much
 higher than that shown here (Ref, 9,  Appendix D).  It is  thus expected that,

-------
                                  - 18 -
for most coal feeds,  the total sulfur in the product coal will be higher
than that used here.   Though the total sulfur has been decreased remarkably,
the content would indicate the need for stack gas scrubbing on the boiler
furnace stack.  This,  however, would defeat the purpose of using product
coal for boiler fuel.


           For some coals, the product may be used as fuel so that emissions
 meet Federal regulations for new installations.  It has been estimated (10)
 that the percentage  of Appalachian coals meeting the requirement of 1.2 Ib
 S02 emissions per million Btu could be increased from about 10% to 40%.
 Due to variations in  pyrites removal and increase in sulfate content,  these
 coals would, of course, have to be tested.  That some coals can be desulfurized
 to meet existing regulations has been recently reported (11).


     4.2.8  Minor Vents

          It is expected that the effluents from minor vents in the process
will be collected.  The moisture and solvent vapor will be condensed and
returned to  the system.  The net vent gas can be incinerated in the utility
furnace.

4.3  Liquid and Solid Effluents

     4.3.1  Coal Storage and Preparation

          The major liquid and solid effluents from this area consist of
rain runoff and wash water from coal dust removal.  This water should be
sent to a storm pond where solids can settle out.  If there are no spills
of organic materials  in the process area, storm drainage from this area can
also be sent to this  holding pond.  After sufficient settling time, the
water from this pond can be used as raw process water.  The pH of the pond
water can be corrected  for acid content by limestone addition to the pond
circuit or the treatment can be accomplished in the makeup Water Treatment
Section.  The pond should be large enough to prevent contamination by
overflow and, if the soil is such that seepage would be a problem, the
bottom of the pond should be lined with clay, concrete or other impervious
material.

     4.3.2  Reaction and Sulfur Removal Sections

          There are no  liquid or  solid plant effluent streams from the
Reaction and Sulfur Removal  Sections.

     4.3.3  Product Drying Section

          The only effluent stream from the Product Drying Section is the
product itself.  This product contains part of the sulfur input to the plant,
much of the minor element input and the major part of the trace element
input.  The water and solvent removed from the coal in this section are
returned to  the process.  The further transportation, use or storage of the
product is not specified, but enclosed transport should be used to prevent
dusting problems.

-------
                                - 19 -
     4.3.4  Irou Sulfate Recovery Section

          The effluent ^ from the Iron Svil fate Recovery Section consists mainly
of ferrous and ferric sulfate; " The moisture content of this material as
well as its Disposition, are unspecified.  There doesn't seem to be a simple
solution to the disposition problem as the material is water soluble and
will be acidic.  This problem is considered further under Potential
Improvements .

     4.3.5  Sulfur Recovery Section

          l
-------
                                  - 20 -


                         5.  THERMAL EFFICIENCY


          The basic thermal efficiency of the Meyers' Process,  using the
present design, is estimated to be 92,1% (see Table .4).  This is the heat-
ing value of the net product (total product less 13,234 Ib/hr (dry) that is
burned to generate steam) divided by the heating value of input coal.  If the
heating value of the by-product sulfur is included, the thermal efficiency
rises to 92.5%.  Results are summarized in Table 4.

          It will be necessary to remove dissolved solids (other than iron
sulfates) from the reaction section water circuit.  One way of accomplishing
this  is  to  remove the iron sulfates in a water purge  stream instead of
filtering.  It is then unnecessary to evaporate a large amount of water and
the  total thermal efficiency rises to about 92.6%.  Debits (mainly, sulfuric
acid  makeup) occur, however, in this type of iron sulfate removal;  these
are  discussed  in Section 8.

-------
                       -  21 -


                       Table 4

                Thermal Efficiency


Net thermal e'fficiency             92.1%

Including sulfur product           92.'5%'

Without water evaporation          92.6%
  in iron sulfate removal*
*  See Section 8 for a description of this
   alternative and the debits thereby incurred.

-------
                                 -  22 -


                           6.  SULFURBALANCE
          A detailed sulfur balance for the Meyers' process is shown in
Table 5.  In the present design, most of the sulfur exits the plant in
solids; the boiler stack is the only source of gaseous sulfur emission.
As indicated earlier, most of the sulfur in the coal product, is in the
form of organic sulfur not removed in the processing.

-------
  - 23  -
Table 5
Sulfur Balance
Ib/hr
Sulfur Into Plant
In coal feed 7,836
Pyritic 6416
Sulfate 80
Organic 1340
Sulfur Out of Plant
In product coal 1, 788
Net product coal 1,663
Boiler stack gas 125
In coal loss 2
In FeSO^ 1,828
In Fe2(S04)3 1,780
Product sulfur 2,438
Total sulfur from plant 7,836

Percent

100.0
81.9
1.0
17.1

22.82
21.22
1.60
0.03
23.33
22.72
31.11
100.0

-------
                                   - 24 -
                           7.  TRACE' ELEMENTS
          The Meyers  process offers an excellent example of how potentially
hazardous trace elements can buildup in a coal treating plant.  Reference to
Figure 2 shows that the only egress of water from the process (other than
minor vents) occurs with the product coal in Stream 5.  (An unknown amount
of water leaves with the iron sulfate in stream 18 as surface moisture and
water of hydration.)  The concentration of trace elements that are soluble
will build up in the water recycled to the Reaction Section.  Although the
concentration can be limited by withdrawing a purge stream from the cir-
cuit, as indicated in a later section, the concentration level of dissolved
solids is still somewhat arbitrary.

          Analyses furnished by EPA for minor and trace elements in a Lower
Kittanning coal are shown in Table 6 for both treated and untreated coal.
The  table indicates significant reductions in calcium, copper, iron,
magnesium, manganese, nickel, potassium, sodium, sulfur, titanium and zinc.
Some elements of interest, such as arsenic, are below the limits of analysis
and whether or not these are dissolved is unknown.

          Table 7 shows analyses for trace elements in a treated and
untreated Lower Kittanning coal (reference 8, p. 189).  Elements that are
depleted by-action of the pyrites  leach solution are  arsenic, boron,
beryllium, chromium, copper, fluorine, manganese, nickel, selenium and zinc.

           From the  viewpoint that  the  product coal  contains less  of some
 potentially hazardous elements,  leaching  of  these  elements  is beneficial.
 It should  be  kept  in mind, however,  that  this leaching will concentrate
 these  elements  in  a  small  area  (depending on the method  used for  disposing
 of the purge  from  the reaction water circuit).   More  work is necessary to
 define potential problems  from  trace elements.  A  recycle system would be
 advantageous  in ascertaining the  extent  of dissolved  solids buildup.

-------
              -  25 -
             Table 6

   Minor and Trace Elements In
  Coal Feed (Lower Kittanning)
and Product Coal (from EPA),  .ppm
Element Method Untreated
Aluminum
Antimony
Arsenic
Beryllium
Bismuth
Boron
Cadmium
Cadmium
Calcium
Chloride
Chromium
Chromiium
Cobalt
Copper
Copper-
Fluoride
Germanium
Iron
Iron
Lead
Lead
Lithium
Magnesium
Manganese
Manganese
Mercury
Mercury
Molybdenum
Nickel
Nickel
Nitrogen
Potassium
ES 19000.
ES <2.
ES <2.
ES Kl.
ES *1.
ES 66 .
AA 2.4
ES <5.
ES 1100.
NA 8600.
AA 30.
ES 44.
ES 11.
AA 12.
ES 40.
IE 17.
ES 22.
AA 40000.
ES 33000.
AA 21.
ES 80.
ES 9.
ES 1300.
AA 28.
ES 40.
AA 0.5
ES <0.2
ES 220.
AA 50.
ES 88.
COU 3000.
ES 6600.
AA - Atomic Absorption
ES - Emission Spectrochemical
NA - Neutron Activation
IE - Ion Electrode
COM - Combustion
COU - Coulometric
G - Gravimetric





                                         Treated

                                         22000.
                                            66.
                                             2,0
                                           440.
                                          8500.
                                            32.
                                            42.
                                            15.
                                             7.0
                                            12.
                                            18.
                                            22.
                                         16700.
                                         19000.
                                            29.
                                            82.
                                             9.
                                           880.
                                            15.
                                            12.
                                             0.6
                                           •c-0.2
                                           220.
                                            30.
                                            44.
                                          3000.
                                          4400.

-------
             - 26 -
        Table 6 (Cont'd)

   Minor and Trace Elements In
  Coal Feed (Lower Kittanning)
and Product Coal (from EPA), ppm
Element Method
Samarium
Selenium
Silicon
Silver
Silver
Sodium
Strontium
Sulfur
Tellurium
Thorium
Tin
Titanium
Vanadium
Vanadium
Zinc
Zinc
Zirconium
ES
ES
ES
AA
ES
ES
ES
COM
ES
ES
ES
ES
NA
ES
AA
ES
ES
Untreated
X10.
<10.
66000.
0.98
1.
660.
44.
33000.
<10.
<10.
2.
440.
22.
44.
32.
40.
<4.
AA - Atomic Absorption
ES - Emission Spectrochemical
NA - Neutron Activation
IE - Ion Electrode
COM - Combustion
COU - Coulometric




                                         Treated
                                         68000.
                                             0.97
                                             1.
                                           400.
                                            44.
                                         14000.
                                             2.
                                           400.
                                            28.
                                            44.
                                            20.
                                            22.
                                             4.

-------
                                   - 27 -
Element

   Ag
   As
   B
   Be
   Cd
   Cr
   Cu
   F
   Hg
   Li
   Mn
   Ni
   Pb
   Sb
   Se
   Sn
   V
   Zn
                                   Table 7

                           Trace Element Analysis
                                  Fox Mine
                           Lower Kittanning Seam,
                 Clarion County, Pennsylvania (From Ref.  9)
Average Values, oorn
ffntreated
<.l
23.5 + 1.5
16 + 1.7
2.0 +0.6
<.5
94+4.3
25 + 2.4
93.5 + 2.1
0.07 + 0.01
4 + 0.1
24 + 2.5
147 + 5.1
5 + 2.9
<1
17 + 7.2
"C2.5
94 + 11.8
105 + 7.1
Treated
1.1 + 1.1
1.4 + 1.2
13+0
0,6 + 0.2
<.5
40 + 4.5
14 + 0.6
82+0
0.15 + 0.02
15 + 0.6
9 + 1.2
11 + 1.1
12 + 0.6
< 1
X2.5
<2.5
115 + 10
11 + 0.6
ppm. Change
+1.1 + 1.1
-22.1 + 1.9
-3 + 1.7
-1.4 + 0.6
Ind
-54 + 6.2
-11 + 2.5
-11.5 + 2.1
+0.08 + 0.02
+11 + 0.6
-15 + 2.8
-136 + 5.2
+7 + 3
Ind
-15 + 7.2
Ind
+21 + 15
-94 + 7.1
  Change

  N.D.
-94 + 5
 19+9
-70 +
  Ind
-58 + 5
 44 + 6
-12 + 2
 Gain
 Gain
 63 + 6
-93 + 1
 Gain
  Ind
 -85%
  Ind
 Gain
-90 + 1
14

-------
                                  -  28  -
                8.  PROCESS ALTERNATIVES AND IMPROVEMENTS


          One process alternative is the use of a settling tank instead of
hydroclones to reduce the water content of the solids from the reactor
prior to filtration.  This technique was suggested in.reference 8.  The
use of a settling tank allows part of the reaction to take place in the
tank and reduces the size of the reactors.  A cost/efficiency analysis
would be required to determine the best solids concentration technique.

          Another process alternative discussed in reference 8 is the use
of submerged combustion instead of steam to evaporate water before filter-
ing the iron sulfates in the Iron Sulfate Recovery Section.  Although a
detailed cost comparison would be necessary to decide which method of
evaporation is cheapest, it is felt that the use of steam would be the
better of the two.  Low pressure steam can be made available from the
utilities area to give1a steam balance and condensation of moisture from
the large volume of combustion gas is then unnecessary.

          It is felt that recovery of sulfur in a fractionation unit is
preferable to the use of a pressure filter as suggested in Reference  8.
Very little additional heat input is necessary for evaporation of the
solvent.  Again, however, a cost/efficiency evaluation would be necessary
before a choice of units could be made.

          If the Meyiers. process were located near a large power plant,
steam and power requirements might be purchased.  Since the plant location
is, unknown, the production of steam and power has been included in the
present design.

          As indicated  previously, it will be necessary to prevent excessive
buildup.of solids dissolved from the coal.  It is possible that the soluble
materials can be  allowed to buildup to  the point where they begin to
precipitate with  the iron sulfates in the Iron Sulfate Removal Section.  If
this steady-state concentration does not affect the  operability of the
process,  then the minor and trace elements can be disposed of with the
iron sulfates.  Otherwise, a purge stream from the process water  circuit
must be included.   One  simple method of accomplishing  this is to replace
the Iron  Sulfate  Recovery  Section shown in figure 2  with  the system shown
in figure  3.  The composition of the streams  in figure 3  are given in
Table 8.

          In this disposal scheme, a fraction  (0.3635) of stream  12,  leach
solution  from filtration in the Sulfur  Removal Section, sufficient to remove
the necessary iron,  is  purged as stream B in  figure  3.  The remainder is passed
to a reactor where  sulfuric acid and oxygen are added  to  convert  sufficient  fer-
rous sulfate to ferric  sulfate  to give  the iron compositions of stream 11  in
figure  2.  Sufficient water is  flashed  to give the water  content  of stream 11
and this  stream is  then returned  to  the Reaction  Section.  Make-up water  (Stream
G) is added to  the  overhead  from  the flash  tank  (stream F) to give stream  16
of figure 2 and this  is passed  to  the  Sulfur  Recovery  Section.  Alternatively,
stream  A  of figure  3  could go  first  to  the Water  Flash Tank and the bottoms
could be  returned to  the Reaction  Section.  In this  case,  the aulfuric
acid and  extra  oxygen would be  added directly to  the Reaction Section.

-------
                                                       Makeup
                             Purge to
                                                        Water
                             Evaporation Pond
from Sulfur Removal
Section of Figure 2
Sulfuric Acid
      Oxygen  —
                    ^>
                                Ferrous  Sulfate
                                Oxidation Unit
                                                                            Stream  16 To. Sulfur
                                                                            Recovery  Section
                                                                            of  Figure 2
                                                                       Water
                                                                       Flash
                                                                                 Stream 11  To
                                                                                Reaction Section
                                                                                of Figure 2
                                                                                                            NJ
                                                                                                            VO
                                            Figure  J

                                Flow Plan  for  Removal of Dissolved
                               Solids  and  Iron from  Meyers   Process

-------
 Stream —*     12
 Chemical
 FeS04
 H2S°4
                                             - 30 -



                                           Table 8

                      Material Balance for Removal of Dissolved Solids
A
6,149
24,824
1,400
B C D E F
3,511 -- -- 1,000
14,174 -- -- 31,600
800 2,462 -- 2,200
G 11 16
1,000
31,600
2,200
            231,000  147,038  83,962   --     --  147,343  20,743  83,657  126,600  104,400
 02            --       --      --     ..    271
TOTAL       281,858  179,411 102,447  2,462  271  182,143  20,743  83,657  161,400  104,400

-------
                                -  31 -



          The debits incurred by this  scheme  are:

          •  An increase in oxygen consumption of  271.Ib/hr

          •  An additional 83,657 Ib/hr.  of process water

         '.  Addition of 2462 Ib/hr of H2S04

          •  An evaporation pond for the purge

          The credits for this scheme are:

          •  Savings of cooling water

          •  Steam  savings for evaporation of approximately
             31,000 Ib/hr of water

          •  No  filter  required for iron removal

It  is  assumed  that  the  purge stream will go  to an  evaporation pond for con-
tainment of  the  solids  and acid.   If naturalization of the acid is necessary,
then  limestone will be  required.

          The  concentration  of  dissolved  solids will be  the weight of solids
dissolved  from the  entering  coal divided  by  the quantity of water purged in
 stream 2 of  figure  3  (83,962 Ib/hr of water).  Thus,  if  1% (ex  P^"^
 of the feed  coal is dissolved,  the concentration  in stream 2  is 23,820  ppm.
 The concentration of  dissolved  solids will vary with the coal feed used.
 Thus, it has been found that the quantity of ash  removed  other than that
 representing pyrites,  varys  over a ten-fold range (Ref.  8, Table 13).   To
 increase the dissolved solids content of the recycle water stream,  "would
 be necessary to  remove part of  the iron sulfate  by precipitation and filtration
 as in the basic  case.   To decrease the solids content it would be necessary
 to purge a larger stream from the system.  The iron content could be madeup
 by precipitation of part of the iron from the purge stream, filtering  it
 and returning it to the system.


           A different  technique for removing dissolved solids has been
 suggested in a recent  design for the Meyers process'^).  This  involves
 evaporation of a portion of  the sulfate stream to essentially dryness
 whereupon the dissolved solids  are removed with  the iron sulfate.


          The process  alternatives and improvements are summarized in
Table 9.

-------
                        -  32  -


                       Table 9

        Process Alternatives and Improvements
   Use settling tank rather than hydroclones to increase
   solids content in stream from reactor.
•  Use submerged combustion to evaporate water from
   iron sulfates solution.


•  Use of a filter to remove elemental sulfur rather
   than fractionation.


•  Purchase steam and electricity.

•  Purge iron from system in solution form to remove other
   dissolved solids.

•  Evaporate a portion of the iron sulfate to dryness and
   remove solids.

-------
                                  - 33 -
                           9.  PROCESS DETAILS
          Power and steam production and requirements are shown in Table 10,
The plant water balance is given in Table 11.

-------
                                    - 34.-


                                   Table-10
                            Power and Steam Balance
                                   Electricity
            Utilities	        kW       600 psia Steam   115 psia Steam
	~"Ib/hr.           Ib/hr.
Consumed
  Coal Preparation                    2,740
  Steam to vaporize H20 in plant                         -*            120,000
  Oxygen Plant                                        23,000
  Power generation                                    97,000
  Cooling water pumps                   420
  Cooling tower fans                    260
  Boiler feed water pumps               110
  Rest of plant                       1,000          	          	
                                      4,530          120,000          120,000

Produced
  Power generation                    4,530
  Steam plant                                        120,000
  From 600 psia Steam                 	          	          120»000
                                      4,530          120,000          120,000

-------
                  - 35 -
                 Table 11

              Water Balance*



 Into Plant

   To makeup water  treatment

   In feed  coal

   In air  to 02  plant
                      TOTAL IN
 Out  of  Plant
   Cooling  tower

    Evaporation   100,000
    Drift          14,160
    Blow Down      21,400
  Ib/hr
 153,850

  20,000

     170


 174,020



 135,560
  In  total product coal

  Vents

  Iron sulfate product

                     TOTAL OUT
  37,600

     860

(Unknown)**

 174,020
*  Excluding potable water and sanitary sewer.

** Any positive value would necessitate increased makeup,

-------
                                  -  36  -
                          10.  TECHNOLOGY NEEDS
          In order to more clearly define and quantify potential pollution
problems, certain areas will have to be investigated in more detail.than
has been done heretofore.  The major items requiring further investigation
are discussed here.

          One major item that may need further work involves overall sulfur
removal from coal.:  As indicated previously, some coals
-------
                             - 37 -
          The quantity of water in the product coal requires quantification.
The suitability of the product for furnace fuel could be affected consider-
ably if the product is sticky.  If the moisture in the product is too
great,  drying may have to be provided and this would decrease the thermal
efficiency.

          A better method of disposal of the iron sulfates is needed since
the quantity of this byproduct for the present case is almost 200 "tons
per day.  Although a holding pond has been assumed in this study for iron
sulfate disposal, it would be preferable if a method were available to
recover the iron and sulfur values from the material.  In any case,  the
quantity of surface moisture and water of hydration leaving with the iron
sulfates should be defined as this will affect the quantity of make up
water.

-------
                                  - 38 -
                           11.  QUALIFICATIONS


          As pointed out, this study does not consider cost or economics.
Also, areas such as coal mining and general offsites are excluded.  These
will be similar and common to all conversion operations.

          The study is based on a specific process design and coal type,
with modifications as discussed.  Plant location is an important item of
the basis and is not always specified in detail.  It will affect items
such as the air and water conditions available, and the type of pollution
control needed.  For example, this study is based on high sulfur eastern
coal, although it can be used on low sulfur western coal.  Because of
variations in such basis items, great caution is needed in making compar-
isons between coal conversion processes since they are not on a completely
comparable basis.

          Some other conversion processes are intended to make SNG or
low-Btu gas fuel, and may make appreciable amounts of by-products, such
as  tar, naphtha, phenols, and ammonia.  Such variability further increases
the  difficulty of making meaningful comparisons between processes.

-------
                                   - 39 -
                            12.  BIBLIOGRAPHY


1.  Magee, E. M., Jahnig, C. E., and Shaw, H., "Evaluation of Pollution
    Control  in Fossil Fuel Conversion  Processes,  Gasification;  Section  1*:
    Koppers-Totzek Process," EPA-650/2-74-009a.  (PB-231-675/AS, NTIS,
    Springfield, Va., 22151), Jan. 1974.

2.  Kalfadelis, C. D.,  and Magee, E. M.,  "ibid.  Synthane Process,"
    EPA-650/2-74-009b,  (PB-237-113/AS,  ibid), June  1974.

3.  Shaw, H., and Magee, E. M.,  "ibid.  Lurgi Process," EPA-650/2-74-009c
    (PB-237-694/AS,  ibid), July  1974.

4.  Jahnig,  C. E., and  Magee, E. M., "ibid. C02  Acceptor Process,"
    EPA-650/2-74-009d,  December  1974.

5.  Kalfadelis, C. D.,  and Magee, E. M.,  "ibid.  Liquefaction:   Section  1
    COED  Process," EPA-650/2-74-009e,  January  1975.

6.  Jahnig,  C. E., "ibid. Section  2, SRC  Process',"  EPA-650/2-74-009f,
    March 1975.

7.  Jahnig,  C. E., "ibid. Section  5, BI-GAS Process/1 EPA-650/2-74-009g,
    May 1975.

8.   Hamersma, J. W., et al.,  "Chemical Desulfurization of  Coal:  Report of
    Bench-Scale  Developments, Vol.  1," EPA-R2-73-173d,  February 1973.

.9.   Hamersma, J. W., et al.,  "Applicability of the  Meyers  Process for
    Chemical Desulfurization of Coal:   Initial Survey of Fifteen Coals,"
    EPA-650/2-74-025,  April  1974.

10.  Lorenzi, Jri,  L.,  et al.,  "Preliminary Commercial Scale Process Engineering
    and Pollution Control Assessment of the Meyers  Process for Removal of
    Pyritic Sulfur From Coal,"  32nd Ironmaking Conference, American Institute
    of Mining, Metallurgical,  and Petroleum Engineers, Cleveland, Ohio,
    April 9-11,  1973.

11.  Meyers, R.  A., Hydrocarbon Processing, p. 73, June 1975.

12.  Nekervis, W. F.  and Hensley, E. F., "Conceptual Design of a Commercial
     Scale Plant for Chemical Desulfurization of Coal," Parts 1 and 2, EPA
     Report No.  EPA-650/2-75-051, October 1975.
 *  The section numbers of" references 1, 2, 3, and 4 have been changed to 1
    through 4, respectively.

-------
                                      - 40  -
                                TECHNICAL REPORT DATA
                          (Please read Inunctions on the reverse before completing)
1. REPORT NO.
EPA-650/2-74-009-k
                           2.
                                                       3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE E valuation of Pollution Control in
Fossil Fuel Conversion Processes; Coal Treatment:
Section 1.  Meyers  Process
            5. REPORT DATE
            September 1975
            6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
 E.M.  Magee
            8. PERFORMING ORGANIZATION REPORT NO.

             EXXON/GRU.10DJ.75
9. PERFORMING ORSANIZATION NAME AND ADDRESS
 Exxon Research and Engineering Company
 P.O. Box 8
 Linden, NJ  07036
            10. PROGRAM ELEMENT NO.
            1AB013; ROAP 21ADD-023
            11. CONTRACT/GRANT NO.
            68-02-0629
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park,  NC 27711
            13. TYPE OF REPORT AND PERIOD COVERED
            Final               	
            14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The report gives results of a review of the Meyers process being developed by TRW,
Inc. , from the standpoint of its potential for affecting the environment.  The quan-
tities of solid, liquid, and gaseous effluents have been estimated, where possible,
as  well as the thermal efficiency of the process.   For the purpose of reduced envi-
ronmental impact, a number of possible process  modifications or alternatives  which
could facilitate pollution control or increase thermal efficiency have been proposed,
and new technology needs have been pointed out.
17.
                              KEY WORDS AND DOCUMENT ANALYSIS
                 DESCRIPTORS
                                           b.lDENTIFIERS/OPEN ENDED TERMS
                                                                      COSATI Field/Group
 Air Pollution
 Coal
 Treatment
 Coal Preparation
 Fossil Fuels
 Thermal Efficiency
Air Pollution Control
Stationary Sources
Clean Fuels
Meyers Process
Fuel Gas
Research Needs
13B
21D

081

20M
18. DISTRIBUTION STATEMENT

 Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
    46
                                           20. SECURITY CLASS (Thispage)
                                           Unclassified
                                                                    22. PRICE
EPA Form 2220-1 (9-73)

-------