EPA-6Q0/R-96-006
February 1996
HYNOL PROCESS ENGINEERING:
PROCESS CONFIGURATION,
SITE PLAN, AND
EQUIPMENT DESIGN
By
Stefan Unnasch.
Acurex Environmental Corporation
555 Clyde Ave., P.O. Box 7044
Mountain View, California 94039
EPA Contract No. 68-D2-0063
Work Assignments 1/044, 2/051, and 2/062
EPA Project Officer: Robert H. Borgwardt
National Risk Management Research Laboratory
Research Triangle Park, North Carolina 27711
Prepared for;
U.S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF RESEARCH AND DEVELOPMENT
WASHINGTON, DC 20460
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EPORT DATA
le reverse before comf
'i 1 cdiNIC/\L li
s \ (Please read Ins&uctions on t!
/£< ij, in ii mi mi iiiiiijii
1 REPORT NO, 2.
EPA-600/R-96-006
3. Ill Illl II IIIl fill I I IIIIIII11
1.. PB96 -16 754'9
4, TITLE AND SUBTITLE
Hynol Process Engineering: Process Configuration,
Site Plan, 'and Equipment Design
5. REPORT DATE
February 1996
i. PERFORMING ORGANIZATION CODE
7. AUTHORJS)
Stefan Unnasch
6. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Acurex Environmental Corporation
P. C. Box 7044
Mountain View, California 94309
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-D2-0063, Tasks 1/044,
2/051. and 2/062
12, SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Air Pollution Prevention and Control Division
Research Triangle Park, NC 27711
13. TYPE OF REPORT ANO PERIOD COVERED
Task Final; 2/94 - 6/95
14. SPONSORING AGENCY CODE
EPA/600/13
15.supplementary notes AppcD project 0fficer is Robert H. Borgwardt, Mail Drop 63,
919/541-2336.
report describes the design of the hydropyrolysis reactor system of
the Hynol process. S^NOTE: A bench scale methanol production facility is [being con-
structed to demonstrafe'^-the. technical feasibility of producing methanol from biomass
using the Hynol process. The plant i-s being designed to convert 50 lb/hr (22,7 kg/hr)
of biomass to methanol. The biomass consists of wood, 'and natural gas is used as a
co-feedstock. Compared with other methanol production pro cesses/-direct emissions
of carbon dioxide can be substantially reduced by using the Hynol process.)'"Process
flow rates and gas compositions] are presented in process flow diagrams for the Hy-
nol system and the hydropyrolysis reactor. Safety, permitting, and site development
requirements are described for the Hynol]facility. The details of the instrumentation
and controls for the hydropyrolysis reactor are presented in a piping and instrumen-
tation diagram. Details of the equipment design, cost, and schedule are also docu-
mented./ /
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
€. cosati Field/Group
Pollution Climate Changes
Carbinols
Biomass
Wood
Natural Gas
Pyrolysis
Pollution Control
Stationary Sources
Hynol Process
Methanol
Hydropyrolysis
13B 04 B
07 C
08A.06C
UL
21D
07D -
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
252
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
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FOREWORD
The U.S. Environmental Protection Agency is charged by Congress with pro-
tecting the Nation's land, air, and water resources. Under a mandate of national
environmental laws, the Agency strives to formulate and implement actions lead-
ing to a compatible balance between human activities and the ability of natural
systems to support and nurture life. To meet this mandate, EPA's research
program is providing data and technical support for solving environmental pro-
blems today and building a science knowledge base necessary to manage our eco-
logical resources wisely, understand how pollutants affect our health, and pre-
vent or reduce environmental risks in the future.
The National Risk Management Research Laboratory is the Agency's center for
investigation of technological and management approaches for reducing risks
from threats to human health and the environment. The focus of the Laboratory's
research program is on methods for the prevention and control of pollution to air,
land, water, and subsurface resources; protection of water quality in public water
systems; remediation of contaminated sites and groundwater; and prevention and
control of indoor air pollution. The goal of this research effort is to catalyze
development and implementation of innovative, cost-effective environmental
technologies; develop scientific and engineering information needed by EPA to
support regulatory and policy decisions; and provide technical support and infor-
mation transfer to ensure effective implementation of environmental regulations
and strategies.
This publication has been produced as part of the Laboratory's strategic long-
term research plan. It is published and made available by EPA's Office of Re-
search and Development to assist the user community and to link researchers
with their clients.
E. Timothy Oppelt, Director
National Risk Management Research Laboratory
EPA REVIEW NOTICE
This report has been peer and administratively reviewed by the U.S. Environmental
Protection Agency, and approved for publication. Mention of trade names or
commercial products does not constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Information
Service, Springfield, Virginia 22161.
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1
ABSTRACT
A bench scale methanol production facility is being constructed to demonstrate the
technical feasibility of producing methanol from biomass using the Hynol process. The plant is
being designed to convert 50 lb/hr of biomass to methanol. The biomass consists of wood, and
natural gas is used as a co-feedstock. Compared with other methanol production processes,
direct emissions of carbon dioxide (C02) can be substantially reduced by using the Hynol
process. This report covers the design of the hydropyrolysis reactor system of the Hynol process.
Process flow rates and gas compositions are presented in process flow diagrams for the Hynol
system and the hydropyrolysis reactor. Safety, permitting, and site development requirements
are described for the Hynol facility. The details of instrumentation and controls for the
hydropyrolysis reactor are presented in a piping and instrumentation diagram. Details of the
equipment design, cost, and schedule are also documented.
)
i i i j
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CONTENTS
Section ' Page
ABSTRACT fi i ,
figures Tyl'TTl
TABLES vi i L,
CONVERSION UNITS ' ...... ; fx I
ACKNOWLEDGEMENT ." ¦ Xt '
• j
1 INTRODUCTION . 1
1.1 SITE SELECTION 4
1.2 FACILITY OVERVIEW 5
1.3 REPORT CONTENTS 5
2 DESIGN BASIS 7
2.1 HYNOL FACILITY CONFIGURATION 11
3 SAFETY AND PERMIT REQUIREMENTS 14
3.1 MATERIAL FLOWS 14
3.2 HAZARDOUS MATERIALS HANDLING 19
3.3 PERMIT REQUIREMENTS 21
3.4 APPLICABLE CODES AND REGULATIONS . 22
3.5 ENVIRONMENTAL REQUIREMENTS 23
3.6 NATIONAL FIRE PREVENTION ASSOCIATION (NFPA)
CODES 25
3.7 FIRE AND SAFETY REQUIREMENTS . 27
3.8 CALIFORNIA OSHA REQUIREMENTS 27
3.9 HAZARDOUS MATERIALS REQUIREMENTS 28
4 SITE DESCRIPTION 29
4.1 FACILITIES DESCRIPTION 30
4.2 HAZARDOUS AREA CLASSIFICATIONS 34
4.3 FIRE PROTECTION 34
4.4 UTILITIES 34
4.5 SITE DEVELOPMENT 38
4.6 PAVEMENT AND DRAINAGE 38
4.7 SECURITY 40
!:;iv !
i i
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CONTENTS (CONCLUDED)
Section
4.8 LANDSCAPING AND SITE VISIBILITY
4.9 SIGNS AND GRAPHICS
HPR SYSTEM DESCRIPTION
5.1 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
5.2 CONTROLS
5.2.1
5.2.2
5.23
5.2.4
5.2.5'
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
Startup Procedures .
¦Solids Feed . ..
Solids Removal
Gas Control . . .
Gas Heating . . .
Steam Injection
Operating Procedures
Controlled Shutdown Procedures
Emergency Shutdown Procedures.
Control Hardware
HPR SYSTEM HARDWARE
6.1 INSULATION
6.2 HPR REACTOR
6.2.1 Cyclone
6.3 HPR SOLIDS REMOVAL
6.4 BIOMASS FEED SYSTEM
6.5 PROCESS GAS SUPPLY .
6.6 FEED GAS HEATER
6.7 HOT GAS FILTER
6.8 WATER SCRUBBER
6.9 ZINC OXIDE DESULFURIZATION SYSTEM
42
42
44
45
46
46
53
54
54
54
54
54
55
55
55
EQUIPMENT, SITE DEVELOPMENT, AND MATERIAL COST
PROJECT SCHEDULE
APPENDIX A — SUPPLEMENTAL INFORMATION
APPENDIX B — EQUIPMENT DRAWINGS
. 73
. 81
A-l
B-l
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/
FIGURES
Number Page
1 Hynol process schematic . 3
2 Hynol Case 1 process flow diagram 8
3 Hynol site plan . 31
4 Hazardous area classifications for Hynol facility electrical installation 35
5 Covered process units and spill prevention berm 41
6 The Hynol facility with the methanol synthesis unit in the foreground,
compressors in the middle, and the HPR/SPR/feed system in the
background 57
7 Vacuum-formed insulation 58
8 HPR vessel 59
9 Heater assembly in pressure vessel 67
10 Hot gas filter 68
11 Water scrubber system 70
12 Zinc oxide desulfurization vessel 72
13 Project schedule 82
vi
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TABLES
1 Hynol gas compositions (volumetric %) and flow rates 9
2 Alternate Hynol gas compositions (volumetric %) and flowrates 11
3 Materials flowrates and storage quantities 15
4 Catalysts for the Hynol facility 17
5 Elemental composition of wood ash 18
6 Permit requirements for Hynol facility 22
7 Potentially applicable SCAQMD regulations 24
8 Hazardous locations for electrical installations (. 26
9 Summary of utility requirements 36
10 Electricity requirements 36
11 Natural gas and water requirements for Hynol plant 37
12 Process system size and weight estimate - 39
13 Summary of control and interlock functions 47
14 Lock hopper feeder sequence KS-406 53
15 Specifications for hydrogasification reactor 59
16 Particle size options for biomass feed systems 61
17 Biomass feed system specifications 62
18 Alkali getter ilowrate 63
19 Sand feed into HPR 64
I vi i
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TABLES (CONCLUDED)
Number
20 Process conditions for electric heater
21 Water scrubber configuration
22 Zinc oxide desulfurization system
23 HPR equipment cost
24 SPR equipment cost
25 MSR equipment cost .
26 Site development cost estimate
27 HPR operation materials
28 SPR operation materials
29 MSR operation materials
viii
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CONVERSION UNITS
1 kg = 2.205 lb = 1,000 g
1 Mg = 1,000,000 kg = 2,205 lb = 1.1 short ton
1 mm = 0.0394 inch
1 m = 1,000 mm = 106 jim = 3.28 ft = 39.4 inch
1 m3 = 1,000 liter (L) = 35.3 ft3
1 m3/h = 0.589 cfm (same temperature and pressure)
1 Nm3h = 0.622 scfm, Nm3 @ 0°C, 101.3 kPa, scf @ 60°F, 1 atm
1 bar = 105 N/m2 = 14.5 psi
1 kPa = 1,000 N/m2 = 0.145 psi
°C = (°F - 32)/1.8
1 kJ = 0.948 Btu
1 kW = 3,412 Btu/hr = 1.34 hp
1 @/(m2 • °C) = 0.1761 Btu/(hr • ft2 • °F)
1 quad = 1015 Btu = 1.055 x 1018J
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ACKNOWLEDGEMENT
This report was completed under U.S. Environmental Protection Agency (EPA),
National Risk Management Research Laboratory Contract No. 68-D2-0063, Work Assignments
1/044, 2/051, and 2/062. This effort was funded under the Department of Defense Strategic
Environmental Research and Development Program (SERDP). The EPA project officer was
Robert H. Borgwardt.
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SECTION 1
INTRODUCTION
Producing methanol from biomass offers significant environmental, energy and economic
advantages over other liquid fuel resources. Methanol is a clean fuel for transportation and its
widespread availability will contribute to air quality improvement in most urban areas. Domestic
production of methanol versus imported fuels brings energy security, local jobs, and fuel
distribution advantages. Process simulation studies indicate that the Hynol process should result
in improved efficiencies in methanol production through increased yields over conventional
processes. The process involves production from combined use of biomass and natural gas as
feedstocks, optimizing the stoichiometry for synthesis gas to produce the fuel. The use of
biomass feedstock together with natural gas provides for reduced C02 emissions per unit of
fossil fuel carbon processed compared with separate natural gas and biomass processes.
In accordance with the goals of the Energy Policy Act of 1992 and the National Energy
Strategy of 1991/92, this project is aimed at the development of a technology that will minimize
the cost of producing a liquid alternative vehicle fuel and maximize petroleum displacement
while reducing greenhouse gas emissions from mobile sources. The most practicable strategy for
achieving these goals is to displace petroleum fuels with methanol derived from renewable
biomass supplemented with natural gas a co-feedstock. In the long term, development of
methanol as a primary alternative fuel will facilitate the transition to fuel-cell powered vehicles
that could ultimately replace internal combustion engines and greatly increase fuel economy
while reducing the pollutant emissions responsible for noncompliance with environmental
standards in urban areas.
Among the renewables, biomass is the only energy resource that can displace petroleum
by conversion to a liquid fuel. Although the most practicable strategy for minimizing greenhouse
gas emissions from mobile sources, which account for 30 percent of the United States total, is
to displace gasoline with a liquid fuel derived from biomass, the amount of biomass that could
be produced sustainably on a scale large enough to impact the needs of the transportation sector
is estimated by Oak Ridge National Laboratory to be only 5.5 quads.1 Since a 30 percent
displacement of transportation fuel would require about 7.5 quads in the year 2010 and because
about half of the biomass energy is lost when converted to liquid fuels by existing technologies,
the biomass must be supplemented with an additional feedstock that is compatible with the
chosen alternative fuel. High efficiency of energy conversion, from biomass to liquid fuel and
a capability to leverage the biomass with a compatible feedstock are crucial to achieving
i
1 Graham, R,, et al., "The Economics of Biomass Production in the United States," Second
Biomass Conference of the Americas, Portland, Oregon, August 1995.
1
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maximum displacement of petroleum. Process simulations show that the proposed technology
can, in theory, leverage biomass with natural gas to produce more liquid fuel from a given
biomass supply than any existing process, or combination of processes, while also leveraging the
amount of liquid fuel that can be obtained from domestic natural gas resources and reducing net
greenhouse gas emissions.
Producing methanol from the Hynol process, illustrated in Figure 1, improves the overall
conversion efficiency of methanol production. When methanol is produced from natural gas, the
gas mixture contains an excess of hydrogen that is not converted to methanol. Similarly,
conventional biomass gasification synthesis gas is rich in CO, which must be reacted with steam
to form waste C02 and hydrogen. Conventional biomass gasification systems are also burdened
with the capital cost of the shift reactor and C02 removal processes that are necessary because
the synthesis gas contains too little hydrogen2. The Hynol process allows for the efficient use
of natural gas and biomass as co-feedstocks. However, operating natural gas reformers and
biomass gasifiers on the same site and mixing the synthesis gases in order to achieve a more
optimal stoichiometry is not a feasible alternative to the Hynol process. The methanol reactor
is too sensitive to the stoichiometry of the feed gas when the ratios of hydrogen to CO is close
to 2:1.3 The Hynol process operates with an excess of hydrogen which is possible since
unreacted hydrogen is recycled to react with biomass. The efficiency of the Hynol process is
over 68 percent. This compares favorably with that of conventional biomass gasification where
the efficiency can approach 55 percent. Process efficiencies for the Hynol process are based on
an interactive computer simulation model which has been checked by the U.S. Environmental
Protection Agency/Air Pollution Prevention and Control Division (EPA/APPCD).
There are three steps to methanol production using the Hynol process:
1. Biomass is introduced into the hydropyrolysis reactor (HPR) in the
presence of recirculated ,H2. The HPR produces primarily CH4, H2, and
water.
2. Steam and natural gas are added to the HPR effluent in a reformer or
steam pyrolysis reactor (SPR) where they react to produce H2 and CO.
3. The output from the SPR is then cooled in a heat exchanger and enters
the methanol synthesis reactor (MSR). The unreacted hydrogen and
methane are recirculated from the methanol synthesis reactor back into
the HPR.
With appropriate process design, the intermediate products can be used in the different
process steps to supply required reactants and process heat. The unique features of this process
that improve upon other gasification systems are the use of natural gas as a co-feedstock and the
recycling of excess hydrogen derived from that natural gas to the gasifier. Because biomass
2 Katofsky, R., "The Production of Fluid Fuels from Biomass," Center for Energy and
Environmental Studies, Princeton University, June 1993.
3 Supp, E,, How to Produce Methanol from Coal. Springer Verlag, Berlin, 1990.
2
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STEAM PYROLYSIS
REACTOR (SPR)
CW
NATURAL
GAS
<
STEAM
BiOMASS
GAS CLEAN UP
HYDROPYROLYSIS
REACTOR (HPR)
RECYCLE GAS
STEAM
U1
S3>
O
LU
<
METHANOL
SYNTHESIS
REACTOR
(MSR)
METHANOL
Figure 1. Hynol process schematic.
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contains insufficient hydrogen to convert all of its carbon to alcohol, these improvements
markedly enhance the alcohol yield and reduce production costs. Addition of natural gas
provides a source of extra hydrogen that permits complete conversion of the carbon, and the
addition of steam further increases alcohol production. When the excess hydrogen is recycled
to the gasifier, alcohol yield is again leveraged due to its reaction with C02 to form the methanol
precursor, CO; other biomass conversion processes must purge nearly half of the biomass-
derived carbon as C02, thereby greatly reducing the potential alcohol yield. Because of these
two advantages, alternative fuel production using the Hynol process would both utilize indigenous
resources as feedstock and obtain maximum yield of clean fuel from those resources.
The goals of the overall demonstration project are twofold. First, the principal process
components will be tested at specified conditions in a bench-scale unit with a biomass capacity
of 22,7 kg/h (50 lb/hr) dry basis. Then, these tests will generate design, construction, process,
and operating data for use in the construction of a large-scale plant
The overall demonstration project consists of four phases;
• Phase I — Specifications of Pilot Plant
• Phase II — Hydrogasifier Design, Construction, and Operation
• Phase IH — Methane Pyrolysis Reactor Design, Construction, and Operation
• Phase IV — Methanol Synthesis from Biomass in a Completely Integrated PEot
Plant
This report is the Phase II Design Report. It details the hydrogasifier design and
describes the overall Hynol facility and the HPR system, including the piping and
instrumentation diagram (P&ID) and control systems. This report also includes a cost summary
and a schedule for completion of Phase II of this project.
1.1 SITE SELECTION
Acurex Environmental contacted a variety of organizations who were potential
candidates for participating in a demonstration of the Hynol process. Demonstrations sites
should have the following attributes:
• Land available for bench-scale unit
• Access to utilities
• Accessibility to biomass harvesting or disposal (for example, land fill operators)
Several city-owned land fills and sewage treatment plants were contacted to seek their '
participation in the project. These facilities also had access to digester gas or landfill gas. The
candidates sites were asked to provide space for the bench-scale plant and potentially supply
small amounts of feedstock. While some organizations were interested in the Hynol process as
a potential means of reducing their waste disposal requirements, they all indicated that a bench-
scale facility was too long term a project, and they were interested in a project that consumes
a larger amount of biomass.
University research organizations were also contacted as candidate demonstration sites.
Several university organizations have access to landfills if it were desirable to locate the facility
4
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directly on the landfill site. For a bench-scale facility, this consideration is not essential since
the feedstock quantities should be relatively small. Operating a bench-scale facility would also
be consistent with the goals of university research organizations.
12, FACILITY OVERVIEW
The bench-scale Hynol facility will be built at the University of California, Riverside,
College of Engineering, Center for Environmental Research and Technology (CE-CERT). The
facility will use biomass (initially white wood) and natural gas as feedstocks. After the facility
successfully operates on wood and natural gas, waste biomass feedstocks such as tree trimmings
will be used as a cofeedstock. The feedstocks will be processed into synthesis gas for methanol
conversion. The HPR converts biomass into methane and the SPR converts CH4 into CO and
H2. Temperatures inside the HPR and SPR are 800®C (1470°F) and 1,000°C (1,830°F)
respectively. The pressure in both reactors is 30 to 40 bar (440 psi). Both reactors will be lined
with internal refractory insulation and the outsides will be covered with a steam jacket. The
outside wall temperature of the reactors is below 204°C (400°F). An external insulation layer
will surround the outside of the reactors.
Gas exits the SPR and is cooled in a heat exchanger and processed in a methanol
synthesis reactor. The methanol reactor system operates at 260°C (500 °F) and with pressures
ranging from 30 to 40 bar (440 to 588 psi). It is expected that product methanol will be stored
in an 7,750 liter (2,000 gal) above ground storage tank. Approximately 1,500 liters (400 gal) of
methanol will be produced per day for 24 hour operation.
The facility will also require a natural gas compressor, process gas compressor, air
compressor, steam generator, and nitrogen supply. A compressed natural gas (CNG) fueling
station may provide gas for CNG vehicle fueling and for the Hynol plant.
The system will initially operate with the HPR only, decoupled from the Hynol system.
The HPR will require an external source of process gas. The process gas that is required for
HPR feed contains H2, CO, C02, CH4, N2, and water vapor. For an approximately 8-month
period, H2, CO, C02 and N2 will be provided on site. Tube trailers will be parked at the site
for the duration of test runs (about 2 weeks each) to provide the H2, CO, and N2. C02 will be
stored as a liquid in high pressure cylinders. When operating the decoupled HPR (or HPR and
SPR), the process gas will be burned in a flare. When all three of the Hynol reactors are
operated as an integrated system, the methanol reactor will provide the process gas feed to the
HPR.
13 REPORT CONTENTS
This report was completed under work assignments 1/044, 2/051, and 2/062 of EPA
contract No. 68-D2-0063. The following work assignment tasks are incorporated into this report:
WA 1/044
• Task 1 — Assessing site requirements for construction of a bench-scale test facility.
• Task 2 — Modifying the existing Hydrocarb hydrogasifier design for the Hynol
system.
5
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• Task 3 — Preparing piping and instrumentation diagram (P&ID) for gasification
system
• Task 4 — Preparing equipment lists and cost estimates for gasification system
components
WA 2/051 and 2/062
• Task 1 — Permit Requirements
• Task 2 — Hot Gas Filter
• Task 3 — Biomass Feed System
• Task 4 — Water Scrubber
• Task 5 — Zinc Oxide Desulfurization Unit
• Task 6 — Prepare Final Report
The report covers the design of the hydropyrolysis reactor (HPR) system of the Hynol
process. Flowrates and components of the overall Hynol process and HPR system are described
in Section 2. Section 3 documents the site requirements in order to provide a basis for
generating construction documents and facilitate obtaining permits. The materials generated,
stored, and transported to and from the site are discussed here in order to identify materials
handling permits, facilities, and other requirements. Codes and regulations that apply to the
facilities and materials are presented next. Section 4 discusses the site plan, process areas, and
facilities and how these will meet code requirements. Section 5 describes the details of piping,
instrumentation, and controls for the HPR system. Equipment designs and hardware
configurations are described in Section 6. Section 7 includes the equipment, consumable
material, and site development costs, and Section 8 includes the schedule for the overall Hynol
system construction and operation.
6
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SECTION 2
DESIGN BASIS
The Hynol process combines biomass feedstocks with natural gas to improve the
efficiency of biomass conversion. The basic Hynol process consists of two reactions: (1)
hydrogenation (or hydropyrolysis) of the carbonaceous feedstock to produce methane followed
by (2) the endothermic reaction of CH4 with steam to produce H2 and CO (steam pyrolysis or
steam reforming).
t
Figure 2 shows a detailed process flow diagram for the integrated Hynol system.
Compressors, heat exchangers, and other major equipment for the Hynol system are shown on
this drawing. A flowsheet for the integrated system is presented in Appendix A. The flowsheet
tracks the material flows for all of the streams related to the HPR system. The values are for
the 25.8 kg/h bench-scale system. Gas compositions, volumetric flowrates, and elemental
compositions are shown for each stream. Enthalpies for the gas streams are shown as the sum
of the heat of formation plus AH298 (enthalpy of gas components at a reference temperature of
298 K). The enthalpies for the total HPR inputs ideally equals the HPR outlet enthalpy for a
perfectly insulated system.
For methanol production, the CO formed in the steam pyrolysis step is catalytically
combined with the hydrogen in a third step to produce methanol. Excess H2 is recycled as a
feed gas for hydropyrolysis. Biomass is fed into a reactor (HPR) and fluidized with recycled
H2-rich process gas at 30 bar and 800°C. Additional steam can be fed into the HPR or the SPR.
The independent reactions taking place in the HPR can be expressed as:
C + 2ff2 -» CH4 (1)
C * HzO -» CO * Ii1 (2)
C02 + H2 -* CO + H20 (3)
The process gas compositions are shown in Table 1. Unconverted carbon is withdrawn
from the reactor with ash in the form of char. Reactions (2) and (3) are endothermic and
require additional energy input to the gasifier. This is why the conventional gasification
processes need oxygen or air to supply combustion heat by burning some carbon in the feedstock
within the gasifier. In the Hynol process, the thermal energy from recycled gas combined with
7
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C>—^S)
C.J01 ,
F-104
R-101
h-ri'
-<*
TBD
t T
NATURAL
D
Acurex Environmental Corporation
HYNOL
PEL EASED FOR REVIEW
CUT
RELEASED FOR REVIEW
CASE 1
PROCESS FLOW DIAGRAM
PEICA5ED FOR REVIEW
RELEASED FOR REVIEW
tst
8570G001
REVISIONS
REFERENCE DRAWINGS
Figure 2. Ilynol Case 1 process flow diagram,
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TABLE 1. HYNOL GAS COMPOSITIONS (VOLUMETRIC %) AND FLOW RATES8
Stream
h2
CO
co2
ch4
h2o
n2
CH3OH
mol/kgk
HPR out [92]
38.0
13.3
7.4
20.3
19.6
1.3
0
196
SPR out [19]
59.8
20.8
2.8
2.8
13.3
0.5
0
450
MSR out [28]
65.5
10.1
6.1
7.7
0.54
1.5
8.5
1,050
Recycle [7]
71.1
11.0
6.6
8.3
0.00
1.6
1.1
149
Wet biomass [1]: 2.0 kg/kga, Steam [2b]: 1.53 kg/kg, Natural gas [67]: 0.61 kg/kg
a ASPEN process simulation, R. Borgwardt, 10/94
b gmoles per kg on a bone dry basis. Stream [1] after drying contains 0.117 kg H^O/kg.
reactions in the HPR allows for an energy neutral gasifier without the need for an internal or
external heat supply. The hydrogasification reaction (1) between the carbon in feedstocks and
the hydrogen in the recycled process gas is exothermic and provides sufficient heat for the
reactions (2) and (3).
Before entering the SPR, the process gas from the HPR is cleaned to remove particulate
and impurities which may contaminate catalysts in the subsequent reaction steps. Conventional
hot gas clean-up methods can be used for this purpose. Feed natural gas can be added prior to
the HPR filter to cool the gas stream and maintain a lower temperature operating environment.
Other options include cooling the gas in a heat exchanger prior to the hot gas filter.
The process gas is then introduced to the steam reformer (alternatively called the SPR)
where HPR outlet gas and methane feed react with steam to form CO and H2. The steam
reforming can be described by two independent reactions:
CH4 * HzO CO + 3H2 (4)
C02 + H2 — CO + H20 (5)
The reactions are performed at 30 bar and 1,000°C. A catalyst-packed tubular externally-fired
furnace reactor similar to a conventional natural gas reformer furnace reactor is used for the
SPR. Total steam feed for the Hynol process is about 1.3 kg per kg of bone dry biomass.
Natural gas is feed into the SPR at a rate of 0.5 kg per kg of biomass. The II2 and CO
concentrations in the exit gas of the SPR are increased to 60 and 21 percent, respectively. The
process gas is then passed through a gas heat exchanger where it is cooled down. The recovered
heat is used to heat the recycled gas. The process gas is cooled for the methanol synthesis
reactor (MSR) feed. The steam produced in this way is about 1.5 times the biomass feed in
weight, which makes steam production energy self-sufficient within the system.
9
-------
The MSR is a conventional methanol synthesis reactor using a copper-based low
pressure catalyst. The cooled process gas then enters the MSR. The reactions taking place in
the MSR are:
CO + 2H2 -* CH3OH (6)
C02 + 3H2 -* CH2OH + H20 (7)
Methanol synthesis occurs at 30 bar and 260 °C. However, higher MSR pressures (up to 100 bar)
are also feasible and can be tested in the "bench-scale" plant The MSR reactions are highly
exothermic so that the released process heat can be extracted from the MSR and used to dry the
biomass feedstock. Methanol is separated from water in a condenser and fractionated to
produce concentrated methanol. To increase the conversion of CO in the MSR, the
uncondensed gas from the condenser is partially returned to the MSR. Using this approach, the
recycle ratio of the internal loop is 4 moles per 1 mole of input process gas from the SPR. The
net result is a 90-percent conversion of CO to methanol in the MSR. Unlike conventional
processes where CO conversion in the MSR is the most critical parameter affecting the efficiency
losses of the process, the Hynol process reprocesses the unconverted material by recycling the
gas to the IIPR and thus prevents losses of process gas constituents. For this reason, the Hynol
process obtains a high thermal efficiency, even though the CO conversion through the MSR may
be lower than that of conventional processes.
The condenser operates at 50°C. The gas exiting the MSR system is introduced to the
gas heatexchanger mentioned previously, after purging a small amount of gas (3.7 percent of the
recycled gas), which eliminates the accumulation of inert nitrogen in the system and keeps the
nitrogen concentration in the system below 2.5 mole %. The system is designed to accommodate
a range of steam and natural gas feeds. The entry points of the steam and natural gas prior to
the HPR or SPR can also be adjusted as indicated by revised process modeling assessments.
Gas compositions and flowrates can vary for different configurations of the Hynol
process. Process modifications that have been modeled include the following:
• Adding steam prior to the HPR. Adding steam to the recycle gas mixture results
in a lower average temperature to the HPR which may affect carbon conversion
equilibrium and rate. Steam can also be superheated and then mixed with the
recycle gas prior to the inter-heat exchanger (HX-205) which allows for greater
heat recovery from the SPR. The HPR system will be designed for steam inputs
before and after the HPR.
• Using a water scrubber rather than a hot gas filter (F-104) cools the HPR gas and
adds water vapor to the gas mixture. The presence of the water scrubber does not
affect the molar flowrates of HPR exit gases shown in Table 1 (except for steam).
The steam input to the SPR is affected; however, the final SPR output should not
be affected since the appropriate quantity of steam is added to the SPR inlet.
10
-------
• The recycle ratio for the MSR affects the amount of CO and hydrogen that are
recycled to the HPR.
• The purge gas flowrate and assumptions on nitrogen entrainment in the feedstock
voidage affects the nitrogen content of the gas streams.
Table 2 shows an example of the differences in expected gas flowrates for a different
process modeling configuration. The HPR system design is flexible enough to accommodate
flowrates that represent expected differences in process modeling and process configuration. As
an example, two different process simulations resulted in the following process changes:
• 15 percent variation in HPR input and output
• Factor of 10 variation in steam input prior to the HPR
• 25 percent variation in CO input
• Factor of 10 variation in C02 input
• 5 percent variation in hydrogen input
• Factor of 2 variation in methane input for recycle gas simulation
Variations in feed gas inputs can be accommodated within the turndown of most process valves.
If very large turndowns are required to simulate required process configurations, parallel valves
will be installed. Variations in mass flow, velocity, and specific heat need to be incorporated into
process gas heater specifications.
2.1 HYNOL FACILITY CONFIGURATION
The design for the bench-scale biomass-to-methanol plant was updated for the Hynol
Process." This report documents the process modifications for the Hynol process. The HPR
system configuration for the Hynol process includes the following specifications:
System pressure: 30 bar
HPR temperature: 800 °C
TABLE 2. ALTERNATE HYNOL GAS COMPOSITIONS (VOLUMETRIC %) AND
FLOWRATES3
Stream
h2
CO
co2
ch4
h2o
n2
gh3oh
mol/kgb
HPR out [92]
45.7
7.7
2.5
29.1
13.8
1.3
0
164
SPR out [19]
65.6
18.1
1.5
5.7
8.6
0.5
0
270
MSR out [28]
73.8
2.8
0.95
15.0
0.44
1.41
5.65
1,648
Recycle [7]
77.3
2.9
0.99
15.7
0.05
1.6
1.6
139
Wet biomass [1]: 2.0 kg/kg®, Steam [2]: 1.30 kg/kg, Natural gas [67]: 0.55 kg/kg
a Hynol simulation flow sheet D, Y. Dong, 9/8/94
b gmoles per kg of bone dry basis. Stream [1] after drying contains 0.117 kg H20/kg.
11
-------
Solids feed:
Steam feed to HPR:
26 kg/h
up to 5.1 kg/h (260°C)
HPR System Process Flow Diagram
The HPR system will initially be operated independently of the SPR and MSR. Two
elements of the Hynol system will not be available for decoupled HPR operation and will need
to be simulated. Recycle gas will be simulated by mixing gases from tube trailers with natural
gas, steam, and vaporized liquid C02. Since the SPR will not be operating, the inter-heat
exchanger will not operate at a high enough temperature because approach temperatures will
be too low to provide the required HPR inlet temperature. An electric heater will provide
additional heat to the recycle gas. Figure 1 represents an integrated system model that cannot
produce the recycle gas for a decoupled HPR system. A flowsheet for the decoupled HPR
system needs to consider the temperature of the simulated recycle gas since this gas will not be
produced from system recycle but rather from bottled gases.
A process flow diagram for the HPR system is shown in Drawing 8570G002 in
Appendix A. The hydrogen, CO, and nitrogen are fed from battles and mixed to simulate the
recycle gas in the fully integrated Hydrocarb system. Hie inlet gases at ambient temperature are
heated in the heat exchanger by the HPR outlet gas. A separate boiler converts water to steam,
which is injected after the heat exchanger. The mixture passes through an electrical heater
before entering the burner where methane is injected.
The hydrogasifier is fed with a mixture of solids, primarily chipped wood with sand and
an alkali absorbing (gettering) agent. The greenwaste and getter are mixed together and fed into
a day bin and lockhopper; the sand and getter can be fed separately directly into the lockhopper
or mixed with the biomass feed. A screw-feeder meters the solids into the reactor vessel where
they are fluidized.
Methane is used to purge ports along the reactor vessel. Unreacted solids and ash are
removed from the reactor in two ways. The solids are removed directly from the bottom of the
reactor using a lockhopper system. Lighter ash is removed from the top of the bed from an
overflow passage, on the side of the vessel, which empties into a lockhopper system.
An internally-mounted cyclone separates most particles from the exiting gas. The outlet
gas passes through a filter which is pulse-cleaned with nitrogen. The hot outlet gas exchanges
heat with the cold inlet gas.
Some elements of the integrated Hynol system were incorporated in the design of the
HPR system. The SPR uses an air compressor, natural gas compressor, and should use a steam
jacket. All of these systems are common with the HPR system and were incorporated into the
HPR system design. Since the demand for methane and air vary with the different Hynol cases,
the feed requirements were incorporated into the HPR system.
In order to operate the HPR for the most realistic test of the Hynol process, the
flowrates for the HPR system need to be compared with those of the integrated HPR system.
Hie net flow of each component, as well as the total enthalpy into the HPR, should be the same
for the decoupled HPR and integrated Hynol system.
12
-------
The HFR system process flow diagram includes the following features that are of
interest and differ between the theoretical integrated system and the actual decoupled system:
1) H2, CO, C02, and N2 are added from battled gases, heated with a heat exchanger,
and then heated further with an electric heater. These gases simulate some of the
recycled HPR feed.
2) Steam from a steam generator is added upstream of the electric heater. This flow
(stream 68) simulates both water vapor that is in the recycle stream and steam
that is added to the HPR system. The electric heater raises the temperature to
1,000°C. Higher temperatures are difficult to achieve with an electric heater.
3) Natural gas, mostly CH4, is added downstream of the electric heater since the
heater face temperature would be sufficiently high to decompose methane at the
partial pressure in the gas stream. The natural gas that is added downstream of
the heater simulates methane in the HPR recycle gas.
4) Provisions are also made to add natural gas downstream of the HPR. This stream
represents the methane feed to the SPR. About 10 percent of this stream is split
off and used to purge the cyclone in the HPR. The balance of the natural gas is
added after the HPR. For decoupled HPR operation, most of the methane need
not be added to the system.
5) Methanol is present in small percentages in the recycle gas. However, the
methanol would dissociate in a heat exchanger with an 888 °C outlet temperature.
Therefore, for the decoupled HPR system, methanol should be added in the form
of its constituent CO and H2. The mass flow (associated with methanol vapor)
entering the HPR is held constant between the decoupled and integrated systems.
6) Some lockhopper pressurization gas carries over into the HPR. The flowrate of
stream 5 is equal to the flowrate of the biomass feed. Since the lockhopper is
pressurized with nitrogen, the biomass voidage volume, as nitrogen gas, enters the
HPR. The mass and enthalpy of the nitrogen should be considered in the energy
balance for the process. They are included on the flowsheet for the decoupled
HPR.
7) Natural gas is combusted to warm up the HPR prior to start-up. The
corresponding flowrates are shown in the process flow diagram. Nitrogen that is
heated with the electric heater will also be used during start-up operations.
Nitrogen can flow through the electric heater which will prevent the heater wires
from overheating prior to adding simulated recycle gas to the system. Air may
also need to be added upstream of the electric heater to allow for periodic
oxidation of the heater wires.
13
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SECTION 3
SAFETY AND PERMIT REQUIREMENTS
This section documents the materials that are generated, stored, and transported to and
from the site in order to identify materials handling permits, facilities, and other requirements.
Codes and regulations that apply to the facility are presented afterwards.
3.1 MATERIAL FLOWS
Various materials will be received, stored, and shipped from the Hynol facility. Table 3
summarizes the material flows for the facility. Flowrates are shown for continuous process
operation as well as product shipping and receiving. Storage quantities, containers, and pressures
are also indicated in Table 3. Material flows in Table 3 represent those during facility operation.
When the facility is not operating, most materials will continue to be stored on-site. Ash,
sludge, and any waste water will be removed from the site. Methanol will be removed from the
reactor system but will continue to be stored in the storage tank to service vehicle requirements.
Natural gas and water will enter the facility via pipeline. Other materials will be shipped into
and from the facility by truck.
Bottled Gases
Gases will be delivered by tube trailer for the initial phases of operation. C02 will also
be delivered as a liquid in B size bottles, and additional nitrogen will be delivered in A size
bottles. Deliveries of hydrogen, nitrogen, and CO tube trailers and C02 will stop once methanol
is produced on-site. Nitrogen will continue to be stored on site in A size bottles.
Natural Gas
Natural gas is as a cofeedstock for the Hynol process. Natural gas is fed into the HPR
(or SPR) at over 34 bar (500 psi). It also burned for heat energy in the SPR. Natural gas
combustion in the SPR is at low pressure, below 7 bar (100 psi). Natural gas will be compressed
in a fueling system for CNG vehicles. The gas will be compressed to 248 bar (3,600 psi) and
stored in a series of high pressure bottles for transfer to vehicles. The compressor will be able
to provide continuous flow sufficient for the Hynol process. During start up, a natural gas-fired
burner heats the HPR. Gas line pressure will be sufficiently high to feed the SPR combustor
without further compression.
14
-------
TABLE 3. MATERIALS FLOWRATES AND STORAGE QUANTITIES
Process
Shipping
Storage conditions
Material
tlowrate
rate
Quantity
Container
Pressure (gage)
Hydrogen—trailer
41.4 sefm
130,000 scf/d
260,000 scf
2 trailers
2,400 psi
Carbon monoxide—trailer
4.0 scfm
110,000 scf/4d
220,000 scf
2 trailers
2,400 psi
Nitrogen—trailer
1.4 to 48 scfm
120,000 scf/
240,000 scf
2 trailers
2,400 psi
Nitrogen—bottles
0.2 scfm
1,830 scf/wk
1,830 scf
6 A bottles
2,640 psi
Carbon dioxide—bottles
7.5 scfm (52 lb/hr)
1,253 lb/d
2,400 lb
40 B bottles
770 psi
Process gas
130 scfm
0
1,000 scf
3 A bottles
1,400 psi
Natural gas
30 scfm
0
3,000 scf
10 A bottles
3,600 psi
Air low pressure
5275 scfm
0
0
—
80 psi
Air high pressure
60 scfm
0
300 scf
1 A bottle
800 psi
Biomass, as received
—
8,400 lb/wk
17,000 lb
8x16 ft pile
—
Biomass, dry & chips
50 lb/hr
2,500 lb/2db
5,000 lb
4x8x14 ft bin
—
Sand
0.5 lb/hr
350 lb/mo
1,0001b
10 bap
_
Kaolinite
05 lb/hr
350 lb/mo
1,000 lb
10 bags
—
Ash
0.38 lb/hr
250 lb/moc
1,250 lb
5 drums
—
Ash and bed material
1.4 lb/hr
1,000 lb/moc
2,500 lb
10 drums
_
(sand and kaolinite)
SPR catalyst (NiO)
—
850 lb//
8501b
3 drums
—
Methanol catalyst (CuO)
— •
850 lb//
8501b
3 drums
_
ZnO pellets
—
560 lb/mod
5601b
2 drums
—
MnO Pellets
—
200 lb/mo"
2001b
1 drum
—
Methanol
420 gal/d
(f
2,000 gal
Above ground tank
Opsig
City water
18.4 gal/hr
0
0
_
_
Distillation bottoms
2.3 gal/hr
Recycled
100 gal
Frocess tank
600 psi
Scrubber sludge
1 lb/hr (max)
350 lb/moc
3501b
1 drum
—
' Standard cubic feed at 60°F, 14.7 psi. See table of unit conversions.
b Chips will usually be produced on site.
c Material to be removed from the facility.
d Fresh catalysts will be delivered to facility and spent catalysts will be removed.
* No methanol is delivered during facility operation. When the facility is not operating, methanol deliveries up to 2,000 gal may
be made to fill the storage tank for vehicle use. Fuel that is produced at the facility will be used in methanol vehicles.
-------
Air
Natural gas is burned in air with natural gas in the HPR system during start up and in
the SPR system during continuous operation. A compressor provides 55 bar (800 psi)
combustion air for the HPR system during start-up. A blower provides 5.5 bar (80 psi)
combustion air for the SPR.
Biomass
Biomass feed for the process will initially consist of clean white wood. Other feedstocks
may be used later during the project. Wood will be processed on site to the consistency required
for the biomass feed system. The wood will be ground or chipped to a particle size less than 10
mm and dried. Both as-received wood and processed wood will be stored on the site. On-site
chipping is the preferred approach since control of the feed size is important for reliable feeding
into the gasifier.
Methanol
Methanol is produced in the synthesis reactor and stored in an above ground storage
tank. Vehicles will use some of the methanol product. Methanol product may also be removed
from the site by tank truck. When the facility is not operating, methanol may also be shipped
to the facility for vehicle use.
Process Gas
Process gas in the Hynol system is made up of feed gases and the products of the three
reactor systems. The composition of process gas streams at the exit of each of the three reactor
systems are shown in Section 2, Process gas circulates through the Hynol system. The
quantities stored amount to the volume of gas in the reactors, piping, compressors, and buffer
tanks. During shut down, process gas will be purged from the facility and replaced with nitrogen.
Other Solids Feed
Sand is expected to be added to the HPR to help fluidize the biomass. Sand will also
retain heat and may help provide for stable gasification. Sand will also help abrade biomass and
accelerate gasification. Sand will be added to the metering bin through a sand port.
Clay materials like kaolinite will also be added to the gasifier. These materials will
absorb alkali metals like potassium and sodium and prevent their subsequent condensation in
the reactor piping or insulation. Alkali metals can also form sand balls inside the gasifier which
eventually plug the gasifier.
The material inside the gasifier is referred to as the bed. Hie bed will be composed of
sand, clay, ash, and unreacted biomass. Clay materials may also be used to displace sand and
comprise a larger fraction of the bed and improve alkali control.
16
-------
Catalysts
A catalyst is used in the methanol synthesis reactor and the SPR. The sulfur removal
system also contains material similar to catalysts. Catalysts consist of metal and metal oxide
coatings over ceramic substrates. Catalyst substrates are typically 5 mm alumina pellets;
however, many other sizes and shapes are used in other applications.
The catalysts for the Hynol system are shown in Table 4. The composition of catalysts
is usually identified by the manufacturer; however, the morphology of the catalyst and coating
are closely guarded secrets. Catalysts must be periodically replaced as they become deactivated
by contaminants in the process gas.
Ash
Ash will be a byproduct of biomass gasification. Ash will contain minerals that are
present in the biomass feed as well as unreacted carbonaceous material. Table 5 shows the
composition of several wood ash samples. Bed material containing ash will be removed from the
HPR. Ash that contains little bed material will also be removed from the hot gas filter vessel
and from the top of the HPR bed.
Water
City water provides make-up water for steam generators. Steam is fed into the HPR
and SPR. Steam passes through insulating steam jackets on the HPR and SPR. Water is
recirculated from a steam drum above the methanol synthesis reactor and removes the heat
generated from the conversion of process gas to methanol Cooling water is also used to
condense methanol vapor to liquid.
One configuration of the Hynol process uses a water scrubber to cool process gas exiting
the HPR. The water scrubber absorbs contaminants in the gas stream.
Waste Water
Waste water will be produced in the water scrubber and distillation column. Hie water
scrubber will collect particulates, alkali metal compounds, and H2S from the outlet of the HPR.
H2S will be converted to H2S04 in the aqueous solution. Some heavy hydrocarbons and tars
may also be present in the waste water from the water scrubber. Solids will be accumulated in
TABLE 4. CATALYSTS FOR THE HYNOL FACILITY
System
Catalyst
Substrate
Sulfur removal
MnO
5-mm pellets
ZnO
Steam reformer
NiO
12.7 x 9.5 x 4.8-mm rings
Methanol synthesis
CuO/ZnO
4-mm beads
17
-------
TABLE 5. ELEMENTAL COMPOSITION OF WOOD ASH"
Run Fuel
Number
Type
Al
Ba
Be
B
Cd
Ca
Cr
Co
Cu
Fe
Fb
Mg
Mn
Mo
Ni
ro4
K
Ag
Na
Sr
Ti
V
Zn
1
Oak
3200
1880
0.22
121
0.63
169000
4.8
14.0
58.4
5680
6.3
5800
6580
BDL
450
6330
31000
BDL
608
1340
197
75
58.0
3A
Oak
4040
2080
0.24
162
0.68
220000
5.8
14.3
79.3
3920
8.8
7350
6080
BDL
5.75
8730
35200
BDL
950
1580
233
85
138
3B
Oak
3880
2010
0.24
149
0.75
227000
5.0
14.0
765
3810
9,0
7050
5750
BDL
550
8150
36600
BDL
805
1530
222
10.0
45.8
3C
Oak
4020
2080
0.25
173
0.93
209000
4.5
14.0
79.3
3510
9.0
7330
5850
BDL
6.00
8750
30800
BDL
858
1520
246
8J
47.0
3 Mean
Oak
3980
2057
0.24
161
0.79
212000
5.1
14.1
78.4
3747
8.9
7243
5893
BDL
5.75
8543
34200
BDL
871
1543
234
9.1
76.9
3 Std. Dev.
Oak
87
40
0.01
12
0.13
7000
0.6
0.2
1,6
212
0.1
168
169
BDL
0.25
341
3027
BDL
73
32
12
0.8
52.9
• 2
Oak
6100
1970
0.18
127
BDL
210000
55
11.0
56.2
7600
5.0
5900
5650
BDL
5.00
6300
22900
BDL
620
1630
349
14.0
30.0
4
Oak
2460
2600
0.27
181
BDL
305000
35
.125
75.0
1600
55
8350
8100
BDL
3.30
9100
48100
BDL
570
2240
84
3.3
27.8
6
Pine
7150
1550
BDL
200
3.90
192000
65
2.6
105.0
1990
17.0
30800
5700
BDL
2.85
23800
58000
BDL
1310
1160
86
1.3
655
14
Pine
7130
1440
BDL
250
6.25
193000
14.3
4,4
101.0
28200
11,0
28200
8150
BDL
1650
21800
45700
15.0
1140
1190
57
1.1
1060
5
Pine
5620
1220
BDL
159
3.75
160000
5.0
2.3
91.4
1430
35.0
21400
3940
BDL
2.65
15300
43200
BDL
1110
MS
109
1.4
417
16
Pine
7580
1800
BDL
260
1.18
227000
8.8
3.9
111.0
2690
55
34500
9830
22
550
24700
49100
11.0
1160
1390
89
BDL
449
9
Pine
7850
1290
BDL
221
4.45
197000
12.0
35
93.0
4440
14.0
28200
6250
BDL
3.25
18700
46600
145
1850
1100
146
3.2
1150
10
Pine
8800
1430
BDL
224
2.68
209000
11.8
3.6
102.0
7000
75
27900
7100
2.9
4.25
21300
46200
145
1810
1200
124
2.2
920
Pine
9050
1590
BDL
273
0.73
214000
115
4.4
88.3
3100
85
38600
10200
2.6
450
23700
48700
8.3
1440
1450
112
3.2
590
8
Pine
9280
1650
BDL
252
0.68
214000
145
4.0
120.0
5060
6.5
41700
7680
2.9
4.00
28400
55000
6.8
2620
1390
148
'5.2
480
12
Pine
7950
1140
BDL
285
68 JO
129000
18.3
4.4
205.0
4450
19.0
30000
8900
2.9
1550
22000
46700
185
1410
1330
54
1.7
1660
13
Pine
5850
1190
BDL
185
14.0
160000
13.0
2.9
805
2120
113
214000
6680
3.1
550
16500
34100
1Z8
1170
980
82
1.1
650
0 Samples were analyzed by inductively-coupled argon plasma (ICAP) spectroscopy at a commercial laboratory. All results are reported as micrograms per gram (parts per
million mass) of dry sample. Reported values were corrected for field blanks. (Source: Burnet, P. G„ et al., "Effects of Appliance Type and Operating Variables oil
Woodstove Emissions," F.PA-600/2-90-001a [NTIS PB 90-151457], January 1990.)
HDL = Below detection limit.
-------
a settling chamber in the water scrubber. The sludge will be removed during a blowdown
process. Sludge will be neutralized and disposed of off site.
If the methanol product is processed to form anhydrous methanol, the fuel will need to
be processed in a distillation column. The water bottoms from the distillation column will
contain some alcohols and hydrocarbons. Since this water is the product of the methanol reactor
and was produced from a clean gas, it will contain no mineral impurities. The distillation water
will be converted to steam and recycled back into the Hynol process as a feedstock. Distillation
water will be stored in a 100-gal (approximately) buffer tank.
3 J HAZARDOUS MATERIALS HANDLING
Several of the materials used in the facility are classified as hazardous because of their
properties or specific EPA listing, The process will require the handling of flammable gases and
methanol, a flammable liquid. Appropriate precautions will be exercised when handling all
materials. A material safety data sheet (MSDS) will be provided by material suppliers for all
materials. City water, as received wood, and air are the only materials from Table 3-1 that will
not have an MSDS.
This section will be updated with information from MSDSs when they are available. A
Hazardous Materials Management Plan (HMMP) will also be prepared for the facility. This
document will list the quantities of hazardous materials that are stored on site.
Methanol
Methanol is a flammable Equid. It burns with an invisible flame which makes detecting
a methanol fire more difficult than other fires. However, methanol fires burn with less intense
radiant energy. Methanol is miscible with water; so, methanol fires can be fought with water.
Alcohol compatible foams may be desirable for larger methanol fires. Methanol is biodegradable
in the event of a spill; however, a methanol spill must still be prevented in order to prevent
short-term adverse environmental impacts. Methanol spills must not be allowed to enter a sewer
or storm drain. Provisions will be made to prevent rain water from mixing with an accidental
methanol spill and entering the storm drain. Methanol ingestion leads to acute toxicity. Poison
warnings will be placed near methanol dispensers.
Since methanol will be manufactured on site, the site operators will need to prepare an
MSDS for this product. The MSDS will be produced from expected compositions and updated
once methanol is produced on site. An MSDS for chemical grade methanol produced by
Celanese Chemical Company is included in Appendix A.
Bottled Gases
All of the bottled gases are potential asphyxiants. Hydrogen and CO are flammable
gases. Liquid C02 can cause freeze burns. All gases in the facility are under high pressure and
must be handled with appropriate precautions. Hydrogen, nitrogen, and CO are also stored at
165 bar (2,400 psi). An MSDS will be obtained from the gas suppliers for each of the gases.
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Process Gas
Process gas will be composed of similar components as the bottled gases. Process gas
will be in the Hynol system at elevated temperatures.
Natural Gas
Natural gas is classified as a flammable. It contains primarily methane and smaller
quantities of other hydrocarbons as well as a few percent of CO, C02, and N2. The gas company
will provide an MSDS for natural gas.
Biomass
Biomass feed will be produced from white wood. Ground biomass can present an
explosion hazard if its particle size is sufficiently small. A sufficiently high moisture content of
the biomass helps eliminate the explosion hazard. Chipped biomass will not result in particle
sizes that represent an explosion hazard. However, some small particles may be produced and
collected as dust. Measures will be taken to eliminate ignition sources and electrical hazards
from processed biomass. An MSDS will be prepared by the site operators for the processed
biomass.
Other Solids Feed
Risks associated with handling sand and pulverized clay appear to be minimal; however,
an MSDS for each will be provided by the supplier. Clay materials may pose an inhalation
hazard due to their fine particle size.
Ash
Ash may be classified as a hazardous materials because of its metals content.
Determining whether ash is hazardous is based on the results of toxicity characteristic leaching
procedure (TCLP). However, since the ash originated from biomass, it should be no more
hazardous than burned wood. Efforts will be made to utilize the ash from this project as an
agricultural supplement. Ash should contain potassium, valuable fertilizer. Used bed material
will contain ash, sand, and kaolinite. Sand is also a valuable agricultural supplement for many
soils.
Ash poses hazards for handling because it will be in the form of a fine dust. Since the
ash will be produced on-site, the site operators will prepare an MSDS for the ash. The MSDS
will be based on expected ash properties and updated after ash is produced on site.
Catalysts
Catalysts may be hazardous because they contain heavy metals. Fine dusts can be
produced when catalysts are handled and these can present an inhalation hazard. Catalyst spills
from accidental handling must be cleaned up to avoid possible ground water contamination if
rain water or rinse water contacts the catalyst, MSDSs will be provided for fresh catalysts by the
catalyst manufacturers. An MSDS may also be required for spent catalysts.
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Waste Water
Waste water from the water scrubber will contain particulates, H2S04, heavy
hydrocarbons, and dissolved gases. Water circulates through the water scrubber, particles are
removed, and the water is cooled and recirculated. The waste water will be treated in the
following steps:
• Remove settled material as sludge
• Neutralize of sludge to a pH of 7
• Strip dissolved gases from the sludge and collect on a carbon absorption system
• Ship sludge for disposal
An MSDS will be prepared for the treated sludge.
3 J PERMIT REQUIREMENTS
The Hynol facility will require following permits and approvals:
• Building permit
• Air emissions permit
• Methanol storage tank emissions permit
• Hazardous materials storage permit
• California Environmental Quality Act (CEQA) documentation
• Storm drain permit
All of these permits can be readily obtained for the project. The University provides
building permits for CE-CERT projects. CE-CERT has reviewed the project requirements with
University and City of Riverside officials, who have not indicated any problems with building
permits, and have indicated that a CEQA environmental document will not be required for the
project. Bourns Inc. and the University already have permits for hazardous material storage, and
the quantities considered for this project will not adversely affect these permits. Since this
project is co-sponsored by The South Coast Air Quality Management District (SCAQMD), no
problems in obtaining permits for the MPR combustor, flare, and methanol storage are
anticipated. Since the SCAQMD has been involved in the design of the plant, they are
knowledgeable about the project, and have been helpful in providing information about the
approach to permitting. The University of California, Riverside architects and engineers have
been briefed on the proposed plant and have added input into the siting requirements and plant
design. They will be used in final design stages as consultants to insure that the project complies
with the University health and safety requirements.
Constructing and operating the Hynol facility will fall under the jurisdiction of several
agencies and require a variety of permits. The anticipated permit requirements are shown in
Table 6. Hie actual permit requirements will be determined upon further discussions with the
agencies with permitting authority. Some permit requirements may not be fully defined until
construction plans are submitted. In addition to permit requirements, codes, and regulations are
also discussed in this section.
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TABLE 6. PERMIT REQUIREMENTS FOR HYNOL FACILITY
Agency
Permit or activity
SCAQMD
Methanol storage tank
Process combustion or experimental permit
City of Riverside
Conditional use permit
Plot plan review
Design board review
Building permit — Site and hydrogasification system
Building permit — Steam reforming system
Building permit — Methanol synthesis system
Riverside Fire Department
Hazardous Materials Management Plan
California OSHA (Title 8)
Pressure vessel certifications
Boiler permit
Process Safety Management Plan
3.4 APPLICABLE CODES AND REGULATIONS
The primary codes and regulations that apply to this type of facility are shown below;
SCAQMD standards and prohibitions
Uniform Fire Code
"National Fire Protection Association (NFPA) 30 Flammable and Combustible Liquids
Code
NFPA 30A Automotive and Marine Service Station Code
NFPA 52 Compressed Natural Gas (CNG) Vehicular fuel systems
NFPA 321 Standard for Basic Classification of Flammable and Combustible Liquids
NFPA 325M Fire Hazard Properties of Flammable Liquids, Gases, and Volatile Solids
NFPA 496 Standards for Purged and Pressurized Enclosures for Electrical Equipment
NFPA 497A Recommended Practice for Classification of Class I Hazardous Locations
for Electrical Installations in Chemical Process Areas
NFPA 70 National Electric Code
Uniform Building Code
Uniform Plumbing Code
Uniform Mechanical Code
California Code of Regulations, Title 8, Industrial Relations
Boiler and Pressure Vessel Codes (ASME)
Code for Pressure Piping (ANSI)
29 CFR 1910 Occupational, Health, and Safety Administration 40 CFR116 Designation
of Hazardous Substances
40 CFR 117 Determination of Reportable Quantities for Hazardous Substances
40 CFR 260 Hazardous Waste Management
40 CFR 261 Identification and Listing of Hazardous Waste
22
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Local authorities will address which codes are applicable and the procedures for the
review process, submitting plans, and applying for permits. Additional local requirements may
also apply.
3.5 ENVIRONMENTAL REQUIREMENTS
Several tiers of regulations may be applicable to the Hydrocarb project, at the federal,
state, and local level. These include the National Environmental Policy Act (NEPA), the
California Environmental Quality Act (CEQA), South Coast Air Quality Management District
(SCAQMD) regulations, as well as the federal Clean Water Act (CWA) and other regulations.
National Environmental Policy Act fNEPA)
The purpose of NEPA is to assure that all federal projects take environmental impacts
into consideration. NEPA may be applicable to this project since it is federally funded by EPA.
Complying with NEPA involves preparation of either an Environmental Impact Statement (EIS)
or a Finding of No Significant Impact (FONSI). These documents describe the site location and
the impact of the project upon the surrounding environment, including animal habitats,
groundwater, air quality, wetlands, etc.
California Environmental Quality Act fCEOA)
CEQA is the state version of NEPA, and it requires completion of an Environmental
Impact Record. If required, a combined ElS/environmental impact report may be submitted to
satisfy the requirements of both NEPA and CEQA.
-Reports that present the environmental impact of a facility such as the Hynol facility are
often required under NEPA or CEQA. Due to the small size of the facility, it is expected that
no environmental reports will be required and a negative declaration document will be prepared.
This requirement needs to be verified.
SCAQMD Regulations
There are numerous potentially applicable SCAQMD regulations pertaining to the
construction and operation of the demonstration plant. They are summarized in Table 7.
Because of the research status of this project, the facility may be exempt from a number of rules
under Regulation IV. The main combustion process for the Hynol system is the eombustor for
the SPR system. The eombustor uses 21 Nm3/h (34 scfm) of natural gas or 2 kJ/h
(2.1 MMBtu/hr) which is at the limit of the SCAQMD exemption. Modifications to the SPR
may bring it below the SCAQMD 1.9 kJ/h (2 MMBtu/hr) exemption limit. When the HPR is
operated separately, the process gas will be burned in a flare at a rate of 7.6 kJ/h (8 MMbtu/hr)
The decoupled HPR system will operate for several 1- to 2-week intervals. Afterwards, the HPR
and SPR system will also be operated with the process gas flared. After this initial period of
operation, the process gas will be fed into the methanol synthesis reactor.
SCAQMD will require a permit for the methanol storage tank. The tank will be
equipped with vapor recover for fuel transfer operations between the tank and a vehicle.
Emissions from working losses from tank filling with a tank truck will also be controlled with a
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TABLE 7. POTENTIALLY APPLICABLE SCAQMD REGULATIONS
Rule
Title
Applicability
REGULATION II
PERMITS
219
Equipment not requiring a written permit
pursuant to Regulation 2
(b)(2) possible exemption for combustion
equipment <1.9 kJ/h (<2 million Btu/hr)
run on natural gas or methanol
REGULATION IV PROHIBITIONS
431.1
Sulfur content of gaseous fuels
Possible exemptions:
(d)(2) <0.46 kJ/Nm3 (<300 Btu/scf)
(6) intermittent vents
(7) <23 kg/day (5 lb/day) S
461
Gasoline transfer and dispensing
Vapor recovery for vehicle fueling
462
Organic Liquid Loading
Class B Facility, subject to:
(b)(1)(B) vapor recovery system
(b)(5) record keeping
463
Storage of Organic Liquids
Permit required for methanol storage tank
Possible exemption: (c) <66L (<251 gallons
464
Waste water Separators
N/A
466
Pumps and Compressors
Maintenance
466.1
Valves and flanges
Maintenance
407 -
Liquid and gaseous air contaminants
Subject to: (a)(1) CO > 2,000 ppm vol.
Exemption for: (a)(2) S < 500 ppm vol.
409
Combustion contaminants
Must be < 0.23 g/m3
441
Research Operations
Possible exemption for all of Regulation IV
as an experimental research operation
REGULATION XI SOURCE SPECIFIC STANDARDS
1166
VOC Emissions from Soil Contamination
N/A
1173
Fugitive Emissions of VOCs
Operator inspection, maintenance, and
record keeping requirements for leaks from
pumps, compressors, and pressure relief
valves
REGULATION XIII NEW SOURCE REVIEW
1303
Requirements
BACT for new/modified permit modeling
and emissions offsets
1304
Exemptions
1309.1
Community Bank and Priority Reserve
(b)(2) Priority Reserve for Research
Operations
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vapor balance system. Working losses due to filling the tank with methanol from the facility may
also need to be controlled. The vapors could be fed into the flare or into the SPR combustor.
Clean Water Act TCWA>
The Federal Clean Water Act may be applicable to the Hynol site. A permit may be
required for storm water runoff or any waste water generated from the steam tanks.
Bourns Inc., the owners of the CE-CERT site, have an existing agreement with the city
relating to the use of the storm drain. They do not store any hazardous materials in outdoor,
uncovered areas. Therefore, there is no risk of contaminating storm run off water and the
facility is not required to have a storm drain permit or to monitor storm run-off water. The
Hynol facility will also comply with the requirements pertaining to storm drain at the Bourns site.
All liquid and solids hazardous materials handling operations will take place under covered areas
and within berms to prevent any possibility of hazardous materials being carried into the storm
drain. No water will be diverted to the sewer.
3.6 NATIONAL FIRE PREVENTION ASSOCIATION (NFPA) CODES
NFPA defines hazardous area classifications for the handling of flammable liquids and
gases as well as a variety of industrial materials. The area classifications determine the type of
electrical equipment specified under NFPA codes and recommended practices. The hazardous
area classes below are associated with the corresponding risks.
NFPA Division Hazard
1 Flammable hazard present during normal operation and maintenance
2 Flammable hazard present not normally present
Unclassified No flammable hazard
The equipment used in these areas will also be approved for service with the following
materials.
Class I — Flammable gases, Groups B, C, and D (eg. hydrogen, CO, and methane)
Class I — Flammable liquids (flash point below 38°C (100°F), methanol)
Class II — Combustible dust, Group G (wood flour)
Class III — Combustible fibers, (wood working plants)
Division 1 areas must be surrounded by Division 2 areas. Division 1 and 2 areas must
contain appropriate electrical equipment. Requirements for meeting Division 1 and 2 area
classifications can be met with explosion proof equipment. Intrinsically safe wiring is an
acceptable alternate for some applications. (Intrinsically safe components use such low energy
levels as to preclude an ignition). Equipment installed beyond Division 2 areas does not need
to meet hazardous area or explosion proof requirements.
NFPA code provide recommended practice for the electrical classification of chemical
process areas. Classification diagrams in NFPA 497A cover the situation for the reactor units
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In the Hynol facility. Process equipment is categorized by size, pressure, and flowrate. The
Hynol system fall into the following categories:
Small < 1,320 L (5,000 gal)
Moderate and high pressure, 7 to 34 bar (100 to 500 psi), >34 bar (500 psi)
Low flowrate > 100 gpm
Table 8 shows the extent of hazardous classification for various hazards. The electrical
equipment in the Hynol facility will meet the requirements for electrical installations.
TABLE 8. HAZARDOUS LOCATIONS FOR ELECTRICAL INSTALLATIONS
Description
Reference, magnitude
and material
Extent of classification"
Outdoor leak sources
NFPA 497A, Flammable gases,
liquids, high pressure,
moderate size and flow
15 ft radius down to ground level Division 2
Hydrogen storage
NFPA 497A, Hydrogen
15 ft radius Division 2
Multiple leakage sources
NFPA 497A, Flammable
liquids, high pressure
3 ft around valves Division 2
10 ft from pump alley Division 2
3 ft radius from pumps Division 2
3 ft from vents Division 1
5 ft from vents Division 2
5 ft from potential leaks Division 2
Below grade areas near
leak sources
NFPA 497A, Flammable gases
and liquids
Division 1 with surrounding Division 2 area
Tank vents
NFPA 497A, Flammable liquid
vapor
3 ft radius Division 2
Dispensing equipment
NFPA 30A, Flammable liquid
service stations
18 in. from edge of dispenser,
20 ft horizontally from dispenser,
18 in. above ground Division 2
Aboveground tanks
NFPA 30, Flammable liquid
10 ft from tank Division 2
Vents
NFPA 30, Flammable liquid
vapor
3 ft from vent Division 1
5 ft from vent Division 2
Tank truck unloading
NFPA 30, Flammable liquid
15 ft from tank truck
Equipment enclosures
NFPA 30A, Flammable liquid,
NFPA 52 CNG
Within enclosure Division 1
Dispensing equipment
NFPA 52, CNG Dispensing
10 ft radius from dispenser,
20 ft horizontally from dispenser,
10 ft above ground Division 2
* Distances are specified in ft. 1 m = 3.28 ft.
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3.7
FIRE AND SAFETY REQUIREMENTS
The following list summarizes some important safety and fire prevention provisions for
the site. These provisions will be reviewed with local fire officials and implemented.
Requirements for facility installations and safety documentation will also be reviewed with fire
officials.
• First aid equipment onsite.
• UL-approved fire extinguishers onsite, subject to the following requirements:
— Inspect and test each extinguisher once a month during project installation.
— Affix a tag certifying the charge and workability of the extinguisher.
• Temporary fire protection for the site in accordance with ANSI-A10
"Safety Requirements for Construction and Demolition."
• Materials that meet the following specifications:
— Building materials must be noncombustible and have a UL
flame-spreading rating of 25 or less and a smoke rating of 50
or less.
— Wood products must be UL-listed, pressure impregnated, and
Cre-retardant with a UL flame spread of 25 or less. '
— No PCB or asbestos or PCB- or asbestos-bearing equipment
or materials will be used.
• Three copies of the Material Safety Data Sheet (MSDS), as specified in
the OSHA Hazard Communication Standard.
Periodic safety reviews will be held to evaluate safety procedures and reenforee safety
training with facility operators. Operational and safety procedures will be documented in a
Process Safety Management Plan that is required by OSHA.
3.8 CALIFORNIA OSHA REQUIREMENTS
OSHA requirements cover pressure vessels, worker safety, and process safety.
California Division of Occupational Safety and Health. Pressure "Vessel Requirements
California uses basically the American Society of Mechanical Engineers (ASME) codes.
Pressure vessels must either be constructed and stamped in accordance with the rules of the
applicable ASME Code, or be proved to provide equivalent safety.
All new pressure vessels that are built for the Hynol facility will be ASME-coded. It is
expected that an existing methanol synthesis system that was built and successfully operated in
Germany will be used for this project. This equipment was built to DIN rather than ASME
codes. This system will be documented according to OSHA requirements for non-coded vessels
(Appendix A).
Process Safety
Title 8 contains provisions for process safety for chemical plants and facilities that
handle hazardous materials. Section 5189, Process Safety Management of Acutely Hazardous
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Materials requires the following activities that will be implemented and documented in a Process
Safety Management Plan.
• Process safety information
• Operating procedures
• Training
• Contractors (onsite workers)
• Pre-start up safety review
• Mechanical integrity
• Hot work permit
• Management of change in the process
• Incident investigation
• Emergency planning and response
• Injury and illness prevention program
• Scheduled and periodic inspections
• Employee participation
• Employer consultation
Federal OSHA compliance guidelines and recommendations for process safety are
described in 29 CFR 1910.119. This document provides a helpful guideline for meeting process
safety requirements.
3.9 HAZARDOUS MATERIALS REQUIREMENTS
The storage of hazardous materials is governed by 40 CFR 261. Materials are
designated as hazardous either by their specific listing or by their properties. The hazardous
status of all materials that will be stored at the facility will be determined. Materials that are
residues from processes or unused materials that are residues are considered waste. Hazardous
materials that are also wastes fall under special storage, handling, and transportation
requirements for hazardous waste. Waste materials that may be produced and may also be
designated as hazardous include the following:
• Water scrubber sludge
• Spent catalyst
• Ash and bed material with ash
• Non-recycled distillation bottoms
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SECTION 4
SITE DESCRIPTION
The facility will be constructed at the University of California, Riverside, College of
Engineering, Center for Environmental Research and Technology (CE-CERT).
The Hynol facility will be built in Riverside, California, on a newly developed site
adjacent to CE-CERT laboratories. Hie site is in an industrial property with a nearby railroad
siding for shipping and receiving heavy equipment. There is an existing access road to the
property that can be used to bring in industrial gases, supplies, and equipment and to give access
for construction and site development. Utilities are available for the CE-CERT laboratories,
with ample natural gas, electric, and water reserves accessible. The site also has a 1,590-liter
(6,000 gal) liquid nitrogen storage tank and a 2,100-liter (8,000 gal) liquid C02 storage tank
which could be used to provide gases for the project.
The site plan calls for a site of approximately 4,000 m2 (1 acre), with appropriate
grading, fencing, and landscaping. Precautions will be taken to deal with safety and
environmental hazards as required. The methanol storage area, for example, would be lined and
bermed "to insure containment of accidental spillage. The site will contain process areas and
facilities. Most of the major equipment is identified in the process flow diagram in Drawing
8570G001 in Appendix A, This diagram covers the integrated Hynol system. Different
configurations will apply when the HPR is initially operated without the other process units. The
ratio includes:
• Biomass storage and processing
• Biomass feed (T-805)
• Hydrogasification reactor (R-101)
• Steam pyrolysis reactor (R-201)
• Gas cleanup (F-104, F-205)
• Gas compressors (C-304, C-308)
• Natural gas compressor (C-627)
• Methanol synthesis reactor (R-301)
• Flare area
• Methanol storage tank-
• Catalyst, and ash storage
• Control room
• Steam and C02 generators
• Air compressors and blowers (C-706, C-201)
• Vehicle parking
• Gas trailer parking
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4.1 FACILITIES DESCRIPTION
Site Data
CE-CERT is located at 1200 Columbia Avenue in Riverside, California. CE-CERT
occupies buildings in the east end of a multibuilding-researeh facility owned by Bourns Inc. The
Hynol site will be located in the currently vacant area to the east of the CE-CERT building. The
layout of the Bourns and a topographical map in the vicinity of the site are shown in
Appendix A. The Hynol facility will be located on a portion of Parcel B.
The following considerations apply to the CE-CERT location. The reactor area and
control room can be located in the undeveloped area between a service road and railroad track
right of way. The control room needs to be located in close proximity to the reactor area since
much of the process gas control will be accomplished with manual valves. Low pressure air
compressors are already in place adjacent to the east face of the building. A natural gas
compressor area could be installed here. This area could serve as a natural gas vehicle fueling
station and also provide natural gas to the hydrocarb facility. Air compressors could also be
located here. Tube trailers will provide nitrogen and hydrogen for Phase 2 of the project when
the HPR is operated independently. The tube trailers can be parked in the existing parking lot
and connected to gas supply manifolds. Bottled nitrogen and CO can be stored in an area
adjacent to the service road or the parking lot. The CE-CERT building can be used for operator
offices and small parts storage.
The site is equipped with water, 440 and 460 V power, and 14 bar (200 psi) natural gas.
Site Plan
Figure 3 shows the site plan for the Hynol facility. The facility is arranged around the
gasification system, SPR, gas cleanup facility, and methanol synthesis system. The layout of
equipment is designed to meet hazardous area classification requirements defined by the
National Fire Protection Association (NFPA). The northern end of the facility is beyond the
area requiring classification for hazardous installations. Hie control room is located close to the
exit of the CE-CERT building. Steam generators are located near the north end of the facility
near access to water. C02 evaporators and air compressors will also be located in the northern
end of the facility. The natural gas compressor system is located adjacent to the street to allow
for vehicle fueling. The methanol storage tank is located in close proximity to the methanol
synthesis unit.
The facility is laid out to allow for the eventual delivery and installation of all of the
process systems. The southern and eastern sides of the facility will be paved to allow vehicle
" access.
Biomass Feed
Wood will be stored, processed, and fed into the HPR system. Wood will be piled in
designated storage areas. The wood will be chipped, dried, and stored in a bin. The chipped
wood will be carried by a conveyor to the lock hopper feed system. The feed system will transfer
the chipped wood into the 30 bar (440 psi) HPR vessel.
30
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-X J ;
I i
Voter Line
-X-
->c-
Sterege Aif
SH(?d Siean
¦ 3Q*-0 1/2*
135-6 1/2*
Control
Power Line
/l Valve
Panel
CD
Natural Ssj
Sows and
Storage
4 4-7 7/9
Storog
Gas^f'CO.t;on
Reactor
Stea*
Pyrolys.s
SeoEtfir
~ ea«^p
Gas Compressor
Hethane
Distillation
No Ccrvpressor
Methanol
fieout&tor
KG Dispenser
74'-fe
Gos Tro.Uer
Parking
N
Figure 3. Hynol site plan.
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The biomass feed system will be installed in a structure that holds the hydrogasifier
(HPR) and steam reformer (SPR). All of the units are mounted in the same structure because
of the requirement to minimize distance between reactors for low heat loss. The biomass feed
system consists of a feed hopper and a transport system to lift the biomass to the top of a lock
hopper, Biomass is transferred from the lock hopper into a metering bin and then into the
HPR.
Hydro gasification
Biomass is fed into the HPR system and fluidized with process gas. The HPR products
go to a filter, sulfur removal system, and then to the SPR system. Lock hoppers remove ash
from the HPR. The HPR is a 607 mm (24 in.) internally insulated vessel. The vessel is
surrounded by a 205°C (400°F) steam jacket.
Steam Pyrolvsis
The SPR is an internally insulated vessel with a 205 °C (400 °F) steam jacket. The SPR
is a shell and tube reactor with natural gas combusted on the shell side of the reactor and
process gas reacting inside the tubes.
Methanol Synthesis
Process gas from the SPR is cooled and recompressed before it passes to the methanol
synthesis system. The process gas passes through a inter-heat exchanger and reacts in the
methanol reactor. The reactor is a shell and tube configuration with water boiling on the shell
side to remove heat from the reaction inside the tubes. CO and H2 react to form methanol
inside the reactor tubes. The MSR system includes a steam tank and evaporator to control the
temperature of the cooling water. The reactor and heat exchanger operate at 260°C (500°F)
and are externally insulated. Reacted process gas is cooled in a condenser and liquid methanol
is collected in a separation vessel.
Distillation System
A distillation column will be used to separate methanol from the methanol/water
mixture that is produced in the reactor. Steam provides the energy for the distillation column.
Separating the water from the methanol will allow the methanol to be used as a vehicle fuel. If
water were not removed from the methanol, the product would present a disposal problem since
it could not be used in methanol-fueled vehicles. Methanol with water might be used as a boiler
fuel, but such an end uses has not been identified.
Natural Gas Compressor
A natural gas compressor system provides combustion gas for the HPR during start up
and feedstock gas for the process, and also serves to fuel natural gas vehicles. Gas is stored in
a set of cylinders at 248 bar (3,600 psi). In order to minimize the complexity of the natural gas
compression system, gas for the Hynol system is drawn off of the 248 bar (3,600 psi) system.
Natural gas for the SPR combustor will come directly from the gas line. The gas line pressure
is 14 bar (200 psi) which is sufficiently high to feed the combustor.
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Process Gas Compressors
Process gas is compressed by two compressors. One compresses gas before it enters the
MSR system. The second compressor recirculates gas within the methanol synthesis loop.
Process Gas Flare
Process gas needs to be flared under some circumstances. During start up and shut
down procedures, gas that is purged from the system must be burned. All of the process gas
must be burned during the initial phases of operation when the HPR and SPR operate without
the MSR. The flare area is located in a remote area of the site.
Methanol Storage
Methanol will be stored in an above ground storage tank. The methanol will be
dispensed to provide fuel for methanol vehicles. The storage tank area will have access for fuel
truck deliveries. Areas where fuel is handled will be surrounded by a berm to control spills. A
covered fuel delivery area is being considered to eliminate any risk of methanol spills being
carried away with rain water run off.
Catalyst and Ash Storage
Catalysts will be stored in drums and kept inside a shed. Ash and spent bed material
will be transferred to drums and stored in a shed.
Control Room
The control room will house the system controls. The control computers, control panel,
and alarms will be located in the control room. The control room will provide desks for three
operators. The control room will be located close to the control valve panel.
Steam and CQ2 Generators
An electrically powered steam generator will be located on the north end of the facility.
Liquid C02 will be converted to process gas for the initial operating phase where the HPR
operates independently. Since heat is absorbed by the C02 when it converts from a liquid to a
gas, heat must be added to the C02 to prevent icing of the gas regulators. COz bottles will be
stored in a water bath which will add heat to the liquid C02. The steam and C02 generators
use non-explosion proof heaters and controls which are located beyond the hazardous
classification areas.
Air Compressor and Blower
An air compressor provides combustion air to for the HPR warm-up burner. The
burner operates before process gas is added to the HPR. A blower provides air for the SPR
combustor. The air compressor and blower use conventional non-explosion proof motors and
are located beyond the hazardous classification areas.
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42 HAZARDOUS AREA CLASSIFICATIONS
Figure 4 shows the regions for hazardous area classifications for the Hynol facility. The
hazardous area classifications were based on the NFPA codes and practices in Section 3.6.
Reactors, flammable gas storage areas, gas compressors, the methanol tank, and fuel dispensers
are within classified areas. The steam generator, control room, air compressor, and other
electrical equipment are beyond the classified areas.
43 FIRJE PROTECTION
Fire protection for the Hynol facility will meet the requirements of local fire officials.
Flammable gas detectors will provide an additional means of determining whether there are
leaks in the reactor system. The fire protection system will include the following:
• Flammable gas detectors in the reactor areas
• Fire alarms actuated by the following inputs:
— Manual fire alarm in control room
— Manual fire alarm in reactor area
— Sensors (if any) activating fire alarm (location in vicinity or reactors)
• Fire alarms wired separately from the control system computer
• Visual and audible alarms activated near the control room
Given the small volume of gas contained in the reactors, a fire extinguisher system may
not be warranted. Fire detectors might also be considered for the facility but are not planned
at this time.
4.4 UTILITIES
The Hynol facility will require various utilities that are available from the site.
Electricity will power the compressor, the control room, heaters, pumps, and the solids feed
system. Wiring for controls and telephone access will also be required. Natural gas is used at
low pressure as fuel for the SFR and at high pressure as a process gas and fuel for system start-
up. Water will be used to generate steam as well as for gas cooling. Table 9 summarizes overall
utility requirements for the facility,
Electric power is required for the compressors, electric heaters, outdoor lighting, and
control room. Ample electric power is available on the south and east end of the CE-CERT
building. Electric power requirements are shown in Table 10.
High pressure natural gas will be provided by a CNG fueling system. The fueling system
will store gas at 248 bar (3,600 psi) for vehicle fueling. The gas will be regulated to the required
pressures for the process systems. A 51-rnm (2-inch) line will provide natural gas to the CNG
fueling system at 14 bar (200 psi). A larger natural gas line is currently being routed into the
CE-CERT building from an area behind this building,
The gas line for the Hynol facility will be routed in the ceiling of the CE-CERT building
to its east side. The gas line will pass outside the building and be routed underground through
34
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L
Water Line
Shed
Cov^precsca
c e/owev Generator
Control
Power Line ^ R0on
/^Ponet \ _
I 1 7" Sotfcte
-------
TABLE 9. SUMMARY OF UTILITY REQUIREMENTS
Utility
Capacity
Electric power
Natural gas
Water
Communications
50 A 440Va
50 A 460 V
48 Nm3/h (30 scfm)
15 L/m (4 gpm)
1 telephone, 1 modem, alarm signal
a Actual power requirements to be determined.
TABLE 10. ELECTRICITY REQUIREMENTS
System Component
Requirement (kW)
HPR system:
Compressor — air, C-706
Compressor — natural gas, C-627
Control room
Heater, H-036
Heater — water
Pump — water, P-511
0.1
12
2
30
15
5
Subtotal for HPR system:
64
Additional requirements for integrated system:
Compressor-air, C-207
Compressor, C-304
Compressor, C-308
Heater, H-203
Heater, HPR recycle, H-036
Pump, P-311 (1 hp)
Pump, P-315 (0.2 hp)
Screw-feeder, S-806 (2.5 hp)
52
1
2
30
5
0.5
0.1
2.0
SYSTEM TOTAL
1S6
36
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the same trench that carries power, and control lines. Natural gas and water requirements are
shown in Table 11.
Water will be obtained from an existing connection located adjacent to the guard shack.
(It looks like a small fire hydrant). The water line will be routed above ground over a
landscaped area. It will not pass over any pavement.
Power, natural gas, and telephone lines will be routed in a trench from the east end of
the CE-CERT building. Power and communications lines will be routed in separate conduits.
A spare or oversized conduit will be provided to accommodate additional electrical power
requirements.
TABLE 11. NATURAL GAS AND WATER REQUIREMENTS FOR HYNOL PLANT
Utilities
System component
Requirement
Natural Gas HPR system;
Recycle mixture [6]
SPR feedstock [67]
HPR system subtotal:
7.2 to 13 Nm3/h
(4.5 to 8.1 scfm)
18.3 Nm3/h
(11.4 scfm)
25.6 to 313 Nm3/h
(15-9 to 19.5 scfm)
Additional requirements for integrated system:
SPR fuel gas [12]
16.9 Nm3/h
(10.5 scfm)
TOTAL Natural gas:
42.4 to 48.2 Nm3/h
(26.4 to 30 scfm)
Water
HPR system:
Recycle mixture and steam feed [2]
HPR system total:
0.4 to 5.3 L/h
(0.1 to 1.4 gal/hr)
0.4 to 5.3 L/h
(0.1 to 1.4 gal/hr)
Additional requirements for integrated system:
SPR feed [80]
Make up water
45.4 L/h (12 gal/hr)
18.9 L/h
(5 gal/hr)
TOTAL water:
69.6 L/h
(18.4 g/hr)
37
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4.5 SITE DEVELOPMENT
Site development will include grading the site, preparing concrete footings for process
units, paving portions of the area with asphalt, covering the site with gravel or paving stones, and
installing a fence. Utilities will also be routed to the site as part of the site development
activities. Specifications will be prepared for asphalt work, utility routing, curbs, and fencing and
the installation will be based on the plot plan.
Equipment Footings
Civil engineering drawings will provide the documentation for each concrete footing.
A grading plan will be prepared to indicate the extent and slope of grading. A general soils
report will be obtained and reviewed in preparing the grading plan. Table 12 shows the
estimated height and weight of the major process units.
Grading
The site will require grading for preparation of the facility. A site grading plan was
available from Bourns and shows the elevations for the site. It appears that there is sufficient
land available to obtain fill and relocate removed material on the site.
Seismic Considerations
The entire southern California area is subject to seismic activity. The structures and
foundations will be designed to meet local seismic requirements.
The Southern California area is subject to seismic activity which will require
considerations for seismic factors in the design of structures and foundations. Hie design of
concrete footings for reactor systems depends on the height and weight of the reactor systems.
Appropriate footings and structures will be designed and reviewed by qualified structural
engineers.
4.6 PAVEMENT AND DRAINAGE
The Hynol facility will be adjacent to an access driveway that leads to the Bourns facility.
Truck parking and access areas will be paved with asphalt. Reactors and process areas will be
laid on concrete pads. It is expected that unoccupied areas between process areas will be covered
with gravel fill. Storm water runoff will be protected from accidental methanol spills.
Requirements for pavement and grading include the following:
A. Methanol storage tank and process areas that handle liquid methanol will be
covered. Rain water will flow into drains that will be directed to gutters in the
pavement. The area surrounding the methanol storage tank and tank truck
unloading area will be surrounded with a berm that can hold 110 percent of the
contents of the methanol tank. The truck unloading area will also be covered and
rain water will be directed to gutters in the pavement. This system will contain
a methanol spill and it will also prevent rain during a methanol spill from carrying
38
-------
TABLE 12. PROCESS SYSTEM SIZE AND WEIGHT ESTIMATE
Unit — weight
Structure
System
Footprint/height/weight
(Mg)
weight (Mg)
Gasification
5.5 m x 5.5 m
T-805
2.0
Members 26.9
and reforming
(18 ft x 18 ft) footprint
R-101
8.0
Grating 3.1
12 m (40 ft) height
F-1Q4
4.0
Stairs 5
61 Mg
R-201
8.0
F-205
1.0
Total 35
HX-205
1.0
LH-834 i
0.5x4
Total
26
Methanol
3.5 m x 3.8 m
R-301
3.0
Estimate 2/3 of
synthesis
(11.5 ft x 12.5 ft) footprint
HX-309/313
1.5
Gasification
11.6 m (38 ft) height
T-314
0.5
structure
30 Mg
E-312
0.5
T-310
0.5
Total 23
Total
7
Distillation
10 ft x 8 ft footprint
Estimate
5
Estimate 15
30 ft height
20 tons
Methanol tank
11 ft x 8 ft footprint
Fuel
6.6
Tank 4,6
5.5 ft height
-
11.2 Mg
Natural gas
1.5 m x 4 m
Bottles
3.0
Skid 4.0
compressor
(5 ft x 13 ft) footprint
Compressors
2.0
1.2 m (4 ft) height
9 Mg
8 1 Mg = 1,000 kg = 1.1 short tons
the methanol to the storm drain. Covering the bermed areas will eliminate the
need to remove rain water from inside these areas.
It is expected that the cover over the methanol storage tank and fuel unloading
area will be a pitched sheet metal roof over a steel structure. The structure will
be designed to allow for a tank truck to maneuver underneath it. Footings for the
structure will be off of the paved area where the tank truck travels.
The methanol condenser and other process areas that handle liquid methanol will
be covered with sheet metal that is integrated into the support structure. Berms
will be installed to collect possible methanol spills. Rain water from these smaller
areas will either drip off of the edge of the pitched cover or flow into a drain that
39
-------
is directed to a gutter in the pavement. Figure 13 shows the areas that will be
covered and protected with berms. The methanol processing areas will be isolated
from the fuel storage areas in that the bermed areas will not inter connect.
Liquid methanol pipe runs between process areas will either be over a bermed
area or over a covered trench.
An alternative to covering the liquid methanol processing areas would require
provisions for the removal of rain water that is collected in bermed areas. One
approach is to open a valve that releases rain water when one is certain that no
methanol spills have occurred. While effective, these types of systems may not
meet the requirements of local officials.
Currently, the Bourns facility does not require a storm water permit or storm
water run off monitoring because hazardous materials are not stored outside. A
covered and bermed methanol storage area should maintain this status but needs
to be reviewed with local officials.
B. Parking area and access road will be paved with asphalt.
C. Run off water from the Hynol facility pavement will be routed to the storm drain
that is at a lower grade than the Hynol site. The existing storm drain is expected
to handle the run off from the new pavement areas.
D. Rain water from the process areas will drain into gravel on the site and enter the
soil below.
E. The site will be graded and compacted to accommodate concrete pads for the
facility structures and pavement.
F. Pavement in the parking area will be based upon 9,070 kg (20,000 lb) axle loadings
with a 6.3 km/hr (10 mph) maximum vehicle speed. No concrete wheel stops will
be installed. The facility will be protected with steel pillars.
G. New pavement grades will be established with an attempt to maintain a minimum
grade of 0.4 percent and a minimum grade of 0.4 percent in gutter flow lines.
Figure 5 identifies the covered and bermed areas for the Hynol facility. All areas that
handle solid or liquid hazardous materials will be covered. The processed biomass storage area
will be covered to keep out rain.
4.7 SECURITY
Site security will consist of the existing fence that surrounds the Bourns facility and a
new fence the further encloses the Hynol facility. The fence will be a minimum of six feet high.
The fence enclosing the Hynol site will be locked when the facility is not in use. The site will
be illuminated for evening operation when in use. The site will be equipped with a fire and
safety alarm system.
40
-------
1 m = 3.28 ft
«.~
Power Line
hkturai S-aj
Storage A,r
Sh
iNg
44'-7 7/8'
iN'
\ /
l/S
|X
Valve
Panel
Solids and
BiOI*iQSS
Storage
Gasification
Reactor
Stean
Pyrolysis
Reactor
AsH
Storage
* I
i
Gas CoMpressor^
i.
¦f
NG Cortpressorj
NG Dispenser
;>
Gas
Cleanup
~
\N{
v'
V.
AV V\\i\ i.vi(
?thanol
Unit
Distillation
Regulator
Panel
a
50'
ai
i
25'
fti
X
1
3
I
fr—
o
u
W
7*'-6*
\/
/ \
v
/S
uas i raiier
Parking
S-hrWt 4 rain prei^c-ftim
Flare
Area
-X-
> /
/ \
V /
17'
\ ~
/ >.
~ ^
%/¦
/ V
S s
N'
v
/V
M-
-*r
44-
Figure 5. Covered process units and spill prevention berm.
41
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4.8 LANDSCAPING AND SITE VISIBILITY
The strip of land adjacent to the access road across from the north end of the CE-CERT
building will be landscaped. Landscaping will be designed for aesthetic purposes, ease of
maintenance, and drought resistance (xeriscape). Landscaping will provide slope control and will
consist of ground cover, shrubs, and small trees. Native species will be used if possible. No
sprinkler system will be installed. Landscaping will be watered from a hose connection within
the Hynol site. Watering will only be required to establish plants.
4.9 SIGNS AND GRAPHICS
A high quality, clearly delineated, and coordinated graphics package will identify the site,
areas within the site and components. These graphics will present a positive image for the
project. Proper identification will facilitate safety, identifying areas clearly, and conducting tour
groups interested in the facility. Graphics will be added to enhance the aesthetics of the facility
and assist operators in performing their tasks more efficiently and safely. The following are
preliminary lists of identification and messages that will be communicated by words or graphics.
Identification
Biomass to Methanol Production Facility
Using the Hynol Process
University of California College of Engineering Center for
Environmental Research and Technology
in association with
Acurex Environmental Corporation
Hynol Corporation
Bourns Inc.
Sponsored by:
U.S. Environmental Protection Agency
South Coast Air Quality Management District
California Energy Commission
Control Room
Biomass Processing
Biomass Feed System
Hydropyrolysis Reactor (HPR)
Steam Pyroiysis Reactor (SPR)
Methanol Synthesis Reactor (MSR)
Gas Clean Up
Steam Generator
Air Compressor
Process Gas Compressor
Natural Gas Compressor
Methanol Fuel Storage Tank
42
-------
Gas Flow Control Panel
Power Panel
Materials, Piping, and Conduits
Cold water
High Pressure Steam
Low Pressure Steam
Compressed Natural Gas
Compressed Air
Compressed Process Gas
Methanol
Ash
Waste Water
Intrinsically Safe Wiring
Control Wiring
Power Wiring
Messages and Information
No Smoking or Open Flames Within 25 ft (7.6 m)
Hynol System Process Flow Diagram
Hynol System P&ID
Emergency Exit
No Parking
Gas Trailer Parking
43
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SECTION 5
HPR SYSTEM DESCRIPTION
The HPR system demonstrates the hydropyrolysis of biomass as part of the Hydrocarb
process. Hot hydrogen and other process gases are fed into the HPR, where they react with
biomass in a fluidized bed. H2, CO, and N2 are metered to simulate recycle gas. The gas
mixture is heated in a ceramic heat exchanger and then further heated with electric heaters.
Steam is added to the gas mixture, and the entire mixture is heated to 1,000 °C. Natural gas is
fed into the system downstream of the heaters.
The uncoupled HPR system is intended to simulate the HPR in an integrated Hydrocarb
plant. The HPR system is different from the integrated system in several respects, including the
following:
• HPR feed is provided from bottled hydrogen, CO, and N2 rather than recycled gas
• C02 is stored as a liquid at 41 bar (600 psi). Feeding C02 into the gas
stream requires adding heat to the bottle to make up for the C02 heat
of vaporization.
• Methanol is omitted from the HPR feedstream since it would dissociate
at the high temperatures in the SPR inter- heat exchanger. The mass of
the methanol is represented as CO and H2.
• Methane from the recycle stream is added to the HPR as part of the
"natural gas" feed in order to eliminate potential sooting of the H-036
electric heaters
• Water will be injected into the feedstream as steam, reducing the burden
and therefore the cost of the electric heater
• HPR feed gases have been adjusted so that their net enthalpy matches
that of the integrated system HPR feed
• The heat exchanger following the HPR (HX-038) is similar to that
following the MPR in the integrated system (HX-205). However, heat
exchanger HX-038 will be exposed to 800°C rather than 1,000°C.
44
-------
5.1 PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
The P&ID for the HPR system is shown in drawing 8570G003 in Appendix A. This
drawing shows all of the instrumentation and controls for the HPR system with the bottled gas
feed. The line designation list foEows the drawing. Each gas supply passes sequentially through
regulator pressure indicators control valves, orifice flowmeter, a flow control valve, and a check
valve. Bottled II2, CO, and N2 are fed from separate or mixed tube trailers or individual 6-packs
depending on cost and feasibility. A separate nitrogen supply is used since only N2 flows through
the system during startup. Two-way or three-way valves are used to allow the supply of gas to
be switched during a run if one supply is depleted. The P&ID indicates the position of valves,
regulator set points, and the location of instrumentation including thermocouples, pressure
transmitters, and pressure switches. Valves are shown in their states during normal facility
operation. For example, emergency nitrogen valve, FV-423, on sheet 3 is shown in the closed
position (darkened). The shelf state of this valve is normally opened.
There are two additional N2 supplies: a system supply and an emergency supply. The
system supply of nitrogen is used for two main purposes. It feeds into the solids lockhopper, and
it also passes through a heated, pressurized tank before it pulse-cleans the filter. The emergency
supply replaces the inlet gases to the HPR vessel in the event of temperature or pressure
excursions.
Bottled methane or compressed natural gas is injected into the burner along with
compressed air (during startup only). The burner is equipped with a pilot light and operates
using a burner management system (BMS) that runs on automatic solenoid switches.
Deionized water is converted to steam in a pressurized steam vessel; this steam feeds
into thelnlet gas stream after it exits the heat exchanger and just before it enters the heater.
Temperature readings at various points along the bed are measured using
thermocouples. Pressure measurements at several points along the reactor are made with
pressure differential transmitters. The pressure port lines are purged with methane to keep
them free of particles. A sampling port is used to extract gas samples at the HPR outlet.
There are several levels of protection against over-pressurization. The first is the
pressure regulators on the inlet gas supplies and the subsequent flow control valves and check
valves. If the gas pressures become too high, the pressure relief valve (PSV 029) before the heat
exchanger provides a safety vent for excess gas (which can be flared). A burst disk at the top
of the vessel is a final level of protection against unexpected pressure increases.
There are also several levels of protection against system overheating. Temperature in
the reactor vessel is monitored, and if it rises above a specified point, a high-temperature switch
(TSH 809) shuts off the air, natural gas, and steam, and opens the emergency nitrogen supply.
Similarly, if the temperature of the inlet gases become too high, a high-temperature switch (TSH
027) shuts off the air, natural gas, and steam, and opens the emergency n2.
45
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52 CONTROLS
The following systems are required for the control of the Hynol system:
Process safety alarm and interlocks
• HPR inlet temperature
• HPR recycle gas pressure
• Emergency N2 pressure
• HPR temperature
• HPR pressure
• Heat exchanger pressure
Process controls
• Steam supply
• Gas heater
• Lower bed removal
• Upper bed removal
• Hot gas filter
• High pressure air supply
• High pressure natural gas supply
• Burner
• Gas supply
• Solids feed
Control systems are indicated by control loops in the P&ID. Each control loop connects
identifies instruments, valves, and controls that interact with that system. System controls are
performed by manual valve control, computer input, and automatic computer or controller
operation. Table 13 lists the control systems as well as the instruments and control activation
for each instrument. In some instances, the control actions differ for start up and operational
modes.
5.2.1 STARTUP PROCEDURES
The HPR system will be started with the following sequence of events:
• Flow nitrogen through HPR
• Ignite flare
• Close bypass valve to raise pressure to 30 bar (440 psi)
• Turn on air flow
• Shut off nitrogen
• Turn on gas flow and ignite pilot and burner
• Turn on nitrogen flow
• Turn on electric heater
• Turn off natural gas burner
• Set gas mixture for Hynol conditions including natural gas and steam
• Turn on biomass feed
46
-------
TABLE 13. SUMMARY OF CONTROL AND INTERLOCK FUNCTIONS
Indicator
System
Tag No.
Description
Control Activation
Type
Mode
Steam
LSL-500
Hardware level switch — low
Turns on pump, P-511
Wired
All
Steam
LSH-500
Hardware level switch — high
Turns off pump, P-511
Wired
All
Steam
LSHH-500
Hardware level switch — high/high
Turns on alarm, LAHH-500
¦Wired
All
LAHH-500
Level alarm — high/high
Computer
Steam
LSLL-500
Hardware level switch — low/low
Turns on alarm, LALL-500
Wired
All
LALL-500
Level alarm — low/low
Computer
Steam
T -513
Tank / level gage
Manually fill tank when water level low
Manual
All
Steam
TB -514
Thermocouple
Tank T-509 temperature
Wired
All
TIC -514
Hardware temp controller
TIC-514 controls heater, set point ¦ 240°C
Wired
TSH -514
Hardware temperature switch
Over temperature interlock to tank heater
Wired
Gas heater
TE -017
Thermocouple
TIC-017 control heater H-G36, exit gas set point = 1,0Q0°C
Wired
All
TIC -017
Software temp controller
Computer
Gas heater
TE -025
Thermocouple
TIC-017 turns off heater, face set point - 1,2Q0°C
Wired
All
TSH-025
Software temp switch
Computer
HPR inlet gas
TE -027
Dual thermocouple
Wired
All
temperature
TAL -027
Temp alarm from TE#1
Low set point initiates undertemp alarm TAL-027
Computer
interlock
TAH -027
Temp alarm from TE#1
High set point initiates overtemp alarm TAH-027
Computer
TSHH-027
Hardware temp switch from TE#2
System Interlock: Trips BMS
Wired
Shuts off FV-013, FV-504, FV-704, FV-706, FV-609
Wired
Hydrogen, steam, air, pilot air, methane
Turns off Steam Heater H-509 in T-509
Wired
Turns off heaters H-036, H-104, H-842
Wired
Opens emergency nitrogen FV423
Wired
Opens flare vent PSV-838
Wired
TAHH-027
Temp alarm from TSHH
TSHH-027 initiates over temperature alarm TAHH-027
Computer
HPR recycle
PT -027
Pressure transmitter
Wired
All
gas pressure
PAL-027
Pressure alarm from PT
Low set point initiates underpressure alarm PAL-027
Computer
interlock
PAH-027
Pressure alarm from PT
High set point initiates overpressure alarm PAH-027
Computer
PSHH-027
Hardware pressure switch
System interlock (described for TSHH-027)
Wired
PAHH-027
Pressure alarm from PSHH
PSHH-027 initiates overpressure alarm PAHH-027
Computer
-------
TABLE 13. SUMMARY OF CONTROL AND INTERLOCK FUNCTIONS (CONTINUED)
System
Tag No.
Indicator
Description
Control Activation
Type
Mode
Exhaust gas
pressure
interlock
FT -823
PAH -823
PSHH-823
PAHH-823
Pressure transmitter
Pressure alarm from PT
Hardware pressure switch
Pressure alarm from PSHH
High set point initiates overpressure alarm PAH-823
System interlock (described for TSHH-027)
PSHH-823 initiates overpressure alarm PAHH-823
Wired
Computer
Wired
Computer
All
Emergency N2
pressure
interlock
PSL 411
PAL-411
PSLL-411
PALL-411
Hardware pressure switch — low
Pressure alarm — low
Hardware pressure switch
Pressure alarm from PSLL
Low nitrogen pressure sounds alarm PAL-411
System interlock (described for TSHH-027)
Low nitrogen pressure sounds alarm PALL-411
Wired
Computer
Wired
Computer
All
HPR
temperature
interlock
TE -809
TAH -609
TSHH-809
TAHH-809
Thermocouple
Temperature alarm from TE
Software temp switch from TE
Temp alarm from TSHH
High set point initiates overtemp alarm TAH-809
System Interlock (described for TSHH-027)
TSHH-027 initiates over temperature alarm TAHH-809
Wired
Computer
Computer
Computer
All
HPR
temperature
interlock
TE -810
TAH -810
TSHH-810
TAHH-810
Dual thermocouple
Temp alarm from TE-8l0a
Hardware temp switch from TE-810b
Temp alarm from TSHH
High set point initiates overtemp alarm TAH-810
System Interlock (described for TSHH-027)
TSHH-027 initiates over temperature alarm TAHH-810
Wired
Computer
Wired
Computer
All
HPR temp
alarm
TE -811
TAH -811
Thermocouple
Temperature alarm - high
High set point initiates over temperature alarm TAH-811
Wired
Computer
HPR temp
alarm
TE -812
TAH -812
Thermocouple
Temperature alarm - high
High set point initiates over temperature alarm TAH-812
Wired
Computer
HPR temp
alarm
TE -813
TAH -813
Thermocouple
Temperature alarm - high
High set point initiates over temperature alarm TAH-813
Wired
Computer
HPR pressure
interlock
PT -030
PAL -030
PAH -030
PSHH-030
PAHH-030
Pressure transmitter
Pressure alarm from PT
Pressure alarm from PT
Software pressure switch
Pressure alarm from PSHH
Low set point initiates low pressure alarm PAL-Q30
High set point initiates high press alarm PAH-030
Alarm provides notice to operator. Vessel is
protected by PSE-815.
System Interlock (described for TSHH-027)
High-high set point initiates overpressure alarm PAHH-030
Wired
Computer
Computer
Computer
Computer
All
-------
TABLE 13. SUMMARY OF CONTROL AND INTERLOCK FUNCTIONS (CONTINUED)
System
Tag No.
Indicator
Description
Control Activation
Type
Mode
Heat
FT -836
Pressure transmitter
Wired All
exchanger inlet
PSHH-836
Software pressure switch
High-high set point opens PSV-836.
Computer
pressure
PSV -836
Pressure safety valve
Operator may open PSV-836 by computer selection (HS-836).
HS -836
Computer select switch
Computer
PAHH-836
Pressure alarm from PSHH
High-high set point initiates overpressure alarm PAHH-836
Computer
Bed removal TE -814 Thermocouple
FV -£10 Solenoid valve
HS -610A Computer select switch
HS -610B Local hardware hand switch
Natural gas flows through FV-610 to cool ash hopper at bottom of R-
101. Gas flow also facilitates solids movement through V-S32.
Operator opens FV-610 based on temperature reading
Manual Load
select on LH-833
computer
Bed removal
TE -814
TSH -814
Thermocouple
Software temp switch high
V-832 opens only if TE-814 less than 400"C
Wired
Computer
Load
LH-833
Bed removal
PDSH-832
Hardware pressure switch
Top solids valve, V-832, opens only if pressure difference is less than
100 psi.
Computer
Load
LH-833
Bed removal
ZS
-834
Hardware valve position switch
Top solids valve, V-832, opens only if bottom solids valve, V-834 is
closed (ZS-834).
Computer
Load
LH-833
Bed removal
zs
-832
Hardware valve position switch
Bottom solids valve, V-834, opens only if top solids valve, V-832 is
closed (ZS-832).
Operator selects open or close for V-832, top solids valve.
Operator pulses valve FV-610 to facilitate solids
movement through V-832.
Manual
select on
computer
Load
LH-833
Bed removal
PT
FV
-830
-409
Pressure transmitter
Solenoid valve
Nitrogen flows through FV-409 to pressurize LH-833. All valves are
closed.
Manual
select on
computer
Load
LH-833
Bed removal
PT
-830
Pressure transmitter
Bottom solids valve, V-834, opens only if pressure is less than 1 bar
(100 psi).
Computer
Unload
LH-833
Bed removal
ZS
PV
-832
-829
Hardware valve position witch
Solenoid valve
Bottom solids valve, V-834, opens only if top solids valve, V-832, is
closed (ZS-832).
Vent valve, PV-829, opens only if V-832 is dosed (ZS-832).
Computer
Computer
Unload
LH-833
-------
TABLE 13. SUMMARY OF CONTROL AND INTERLOCK FUNCTIONS (CONTINUED)
Indicator
System Tag No, Description Control Activation Type Mode
Bed removal ZS -834 Hardware valve position switch Top solids valve, V-832, opens only if bottom solids valve, V-834 is Manual Unload
closed (ZS-834). select on LH- 833
Operator opens vent valve, PV-829 computer
Operator pulses valve FV-409 to facilitate solids movement through
V-834.
Operator selects open or close for V-834, bottom solids valve.
Operator closes vent valve, PV-829
Bed removal
FT -830
Pressure transmitter
Operator opens FV-409 to pressurize LH-833 with nitrogen. Solids
Manual
Unload
valves, V-832 and V-834, are closed.
select on
LH-833
computer
Upper bed
TE -815
Thermocouple
Similar to "bed removal" as described above.
Computer
All
removal
TSH -815
Software temp switch high
FV -611
Solenoid valve
HS -611A
Computer select switch
HS -61 IB
Local hardware hand switch
PDSH-822
Hardware diff press switch
ZS -833
Hardware valve position switch
ZS -835
Hardware valve position switch
FV -410
Solenoid valve
PT -831
Pressure transmitter
PV -830
Solenoid valve
Filter
PDT 4)55
Pressure deferential xmtr
Pulse Nitrogen solenoid valve FV-820 opens when pressure drop
Wired
Run
PDSH-055
Pressure diff switch high
exceeds set point OR at programmable time interval OR by operator
Computer
KS -055
Software time switch
manual start at the computer. Pressure set point and valve open
Computer
HS -055
Computer select switch
duration are variable.
Computer
Filter
TE -104
Thermocouple
Wired
All
TIC -104
Software temp controller
Heater H-104 is controlled by H-104 element temp
Computer
Filter
TE -022
Thermocouple
Interlock disables heater H-104 in event of F-104 face over
Wired
All
TSH -022
Software temp switch
temperature
Computer
Filter
TE -821
Thermocouple
Wired
All
TIC-821
Software temp controller
Heater H-842 is controlled by H-842 element temp
Computer
Filter
TE -841
Thermocouple
Interlock disables heater H-842 in event of T-842 face over
Wired
All
TSH -841
Software temp switch
temperature
Computer
-------
TABLE 13. SUMMARY OF CONTROL AND INTERLOCK FUNCTIONS (CONTINUED)
Indicator
System
Tag No.
Description
Control Activation
TVpe
Mode
Air supply
C -706
Provides compressed air
Compressor on/off
Manual
All
Other controls part of package
Natural gas
C -627
Provides natural gas
Compressor on/off
. Manual
All
supply
Other controls part of package
Burner
BSE -019
Flame detector
Burner management system (BMS) controls burner lighting sequence:
Wired
All
(Operator opens valves for air and gas FV-710, 711, 641, 642, 643)
Manual
Operator presses HS-019 on BMS to start sequence.
Wired
BMS closes FV-014 H2 & CO during purge,
Wired
HS -019
BMS sequence start button
verifies FSL-011 flow for 3 minutes,
Wired
Disables FV-639 during purge and flame,
Wired
FSL-011
Hardware purge N2 flow switch
Opens FV-704 and FV-635 (continuous pilot),
Wired
Powers spark BX-021 for 30 sec,
Wired
Opens main air and gas FV-706 and FV-637 for main flame.
Wired
BMS shuts off FV-704, 706, 635, 637 if flame detector BSE-019 off.
Wired
Gas Flow
PDIT-003
Pressure differential indicating
Operator controls hydrogen flowrate through FCV-004 based on
Manual
All
transmitter
PDIT readout.
Gas Flow
PDIT-007
Pressure differential indicating
Operator controls CO flowrate through FCV-008 based on PDIT
Manual
All
transmitter
readout.
Gas Flow
PDIT-011
Pressure differential indicating
Operator controls nitrogen flowrate through FCV-012 based on PDIT Manual
All
transmitter
readout.
Gas Flow
PDIT-607
Pressure differential indicating
Operator controls natural gas/methane flowrate through FCV-605,
Manual
All
transmitter
606, 607, 608, 617, 618, 619, 620, 621, 622, 623, 636, 638, or 640 based
on PDIT readout.
Gas Flow PDIT-703 Pressure differential indicating Operator controls air flowrate through FCV-705 and 707 based on Manual All
transmitter PDIT readout.
-------
TABLE 13. SUMMARY OF CONTROL AND INTERLOCK FUNCTIONS (CONCLUDED)
System
Tag No.
Indicator
Description
Control Activation
Type
Mode
Solids feed
PT -801
PSL -801
PSH -801
ZS -839
ZS -840
LSL -805
PV -802
TV -406A
PV -406B
Pressure transmitter
Software pressure switch
Software pressure switch
Hardware valve position switch
Hardware valve position switch
Hardware level switch low
Solenoid valve
Solenoid valve
Solenoid valve
See sequence table
Computer
All
Solids feed
PT -804
PDIT-403
Pressure transmitter
Pressure differential indicating
transmitter
Nitrogen flows through FCV-404 to pressurize T-805.
Manual
Screw
feed
solids
Solids feed
SIC -805
Screw feeder controller
Controls speed of metering screw feeder SF-805
Wired
Screw
feed
solids
Solids feed
SIC -806
Screw feeder controller
Controls speed of transport screw feeder SF-806
Wired
Screw
feed
solids
-------
522 Solids Feed
Solids feed is accomplished with a lock hopper and metering bin. Valves at the top and
bottom of the lock hopper move the biomass across the pressure barrier. Metering screws in the
feeder control the feed rate. A feed screw moves the biomass into the HPR. Metering screws
and the feed screw operate continuously. The metering screw speed controls the rate of biomass
feed into the HPR. The lock hopper operates with the following sequence which is summarized
in Table 14. The lockhopper is pressurized while both valves are closed. The lower valve is
opened and solids fall into the metering bin. The valve is closed and the hopper is
depressurized. After the valve is depressurized, the top valve is opened and biomass enters to
TABLE 14. LOCK HOPPER FEEDER SEQUENCE KS-406
Description
of event
Trigger
or delay
PV-406A
LockHpr
PV-406B PV-802
tank BagHs
V-839
LH top
V-840
LHbot
Rest state
closed
open closed
closed
closed
Init seq: open vent
LSL-805 low
open
LH depressurized
and V-840 closed;
open LH top valve
PSL-801 < =
50 psia AND
ZS-840 closed
open
LH valve delay
wait 20 sec
Fill lock hopper
wait 10 sec
Close LH top
close
close
LH valve delay
wait 20 sec
Pressurize LJ1
open
Tank drain delay
wait 20 sec
Close tank valve
close
LH pressurized
and V-839 closed:
open LH bottom
PSH-801 > -
730 psi AND
ZS-839 closed
open
LH valve delay
wait 20 sec
Empty lock
hopper
wait 10 sec
Close LH bottom
close
close
LH valve delay
wait 20 sec
Recharge tank
open
a Set points indicated in English units. 1 bar = 14.5 psi
53
-------
fill the hopper. The top valve is closed and the hopper is pressurized with nitrogen. The bottom
valve is opened to allow the solids to fall into the metering bin. The bottom valve is closed and
the procedure is repeated as required.
523 Solids Removal
Solids are removed from the HFR from lock hoppers, LH 833 and 835. For solids
removal, the pressure is vented from the loekhopper while both valves are closed. The lower
valve is opened and solids are removed. The valve is closed and the hopper is pressurized.
After the valve is pressurized, the top valve is opened long enough to allow solids to partially fill
the hopper. The top valve is closed and gas is vented from the bottom hopper. The bottom
valve is opened to allow the solids to fall from the hopper. The bottom valve is closed and the
procedure is repeated as required. Pulse jets of natural gas are available to assist in briefly
fluidizing and clearing any material bridging over the hopper valves.
5J.4 Gas Control
Bottled gases will simulate the recycle gas for the Hynol process (stream 65), Steam and
natural gas will be added later to represent stream 7 of the integrated system. Bottled gas flow
rates will be controlled with manual needle valves that are preset to the desired flow condition.
The process control computer will calculate the flow from differential pressures across orifice
plates. On/off control will be accomplished with a manual ball valve. The control system
computer will initiate emergency shut downs of feed gases.
5.2S Gas Heating
A gas heater raises the gas stream temperature such that it simulates the conditions of
the integrated hynol system. Feed gas is initially heated from ambient temperature in HX-038,
however, these process conditions are different than those of the integrated Hynol system where
the recycle gas is heated in HX-205 (see Figure 1). Natural gas is added downstream of the
heater in order to avoid carbon formation on the heater wires.
5.2.6 Steam Injection
Steam is injected upstream of electric heater H-036. The steam simulates water vapor
in the recycle gas, as well as steam added to the HPR and additional biomass moisture (currently
both are zero). The steam mixes with the gas stream which can subsequently be heated up to
900°C.
52.7 Operating Procedures
After the HFR is started, operation of the HPR requires the following activities:
• Monitoring gas flow rates and temperatures
• Monitoring system pressure
• Adding biomass to the feed hopper
• Removing ash and bed material from the HPR
• Monitoring gas analyzers
54
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These functions are all performed manually. The process monitoring computer will provide
displays on temperature and pressure conditions, gas flow rates, and the position of lock hopper
valves. The process controller will monitor instruments and activate alarms or shut down
procedures as required.
52.8 Controlled Shutdown Procedures
A controlled shut down for the IIPR system consists of the following steps.
52.9 Emergency Shutdown Procedures
Emergency shut down will stop all flow of flammable gases to the HFR and drop the
system pressure. The emergency shut down sequence includes the following steps:
I
• Shut off flammable gases FV-001
• Shut off process steam flow FV-504
• Shut off natural gas flow FV-609
• Stop biomass flow SF-806
• Shut off all electric heaters (H-102, 11-843, H-G36, H-052) except H-566
• Open emergency relief valve FV-838
• Open emergency nitrogen valve FV-423
• Shut off air flow (FV-704, FV-712)
The nitrogen flow through FV-423 is a controlled with an orifice that results in a flow
rate similar to the HPR flow rate at operating conditions.
Emergency shut down in initiated by the computer via inputs from over temperature and
overpressure alarms. In addition, hardwired controls will trigger the emergency shut down
procedure. Computer initiated signals are indicated as high/high alarms in hexagon symbols (see
high pressure alarms FAHH-853 on Sheet 4 of Drawing 8570G003 in Appendix A). Hard wired
switches are indicated by high/high sensors in circle symbols (e.g. PSHH-853).
52.10 Control Hardware
Process control will be accomplished with an industrial controller. Industrial controllers
are more robust that PC-based control systems. The controller will be provide instrumentation
data to a data acquisition computer. The controller will continue to operate even if the data
acquisition computer fails to operate. Computer control inputs will be sent to the controller
from the data acquisition computer.
For a bench-scale system, it is appropriate to control many actions manually. Most
manual control functions will be accomplished by opening or closing a ball valve. Flow rates will
be preset with needle valves. Fine adjustments can be made with needle valves during facility
operation.
55
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SECTION 6
HPR SYSTEM HARDWARE
The layout for the biomass feed, HPR, and SPR structure is shown in Figure 6, The
reactor vessels are arranged adjacent to each other to minimize pipe runs and reduce heat losses.
The MSR system is located on a separate structure. The gasification system structure will be
assembled on site, The process reactors will be delivered and assembled on site. Detailed
drawings for the HPR, hot gas filter, water scrubber, and desulfurization vessel are presented in
Appendix B.
6.1 INSULATION
The HPR system has several different insulation and piping requirements as follows:
• The pipe runs carrying the process gas must be insulated.
• The HPR fluidization zone must be abrasion-resistant.
• Other sections of the vessel must be insulated but do not require
abrasion-resistant material.
Heat losses were analyzed for an HPR system with 200°C steam-jacketed pipes. These
heat losses were found to range from 400 to 660 watts per linear meter of pipe depending upon
the configuration. Figure 7 shows the configuration of vacuum formed insulation for pipe runs.
The fluidized section of the HPR will be insulated with an abrasion resistant refractory, backed
with a low thermal conductivity layer, with an outer layer in ceramic paper.
62 HPR REACTOR
Table 15 shows the configuration of the HPR. The reactor has a 6 inch inner diameter
which is made from refractory lined pipe in the fluidized section of the HPR. Hie freeboard
section and plenum section of the HPR lined with preformed fiber insulation. Figure 8 shows
the configuration of the hydrogasifier.
62.1 Cyclone
An internal cyclone captures fine materials from the HPR. The cyclone is mounted on
the edge of the freeboard section of the HPR. Cyclone fines are returned to the bed from the
cyclone dipleg. Cold flow tests indicated that it was important to prevent flow up the cyclone
dipleg. Two methods were used to keep gas flow from entering up the cyclone dipleg. A gas
ejector was used to create a suction at the bottom of the cyclone. This method was somewhat
unconventional and used a small quantity of natural gas. Another technique is to place a hinged
56
-------
Figure 6. The Hjnol facility with the methanol synthesis unit in the foreeround
in the middle, and the HPR/SPR/feed system in
-------
LONGEST AVAILABLE LENGTH -
01O.OtS
022-9
VACUUM-FORMED CERAMIC FIBER SLEEVE REQUIREMENT
SLEEVE DIMENSIONED TO FIT INSIDE
SCHEDULE 60 24* PIPE (0 22.06 ACTUAL
INSIDE DIAMETER OF THE PIPE)
NOT TO SCALE
A COMBINED LENGTH OF 10'
WILL BE REQUIRED
REVISION A
23 MARCH 9 3
LONGEST AVAOASLE LENGTH
0 22 5
VACUUM-FORMED CERAMIC FIBER SLEEVE REQUIREMENT
SLEEVE DIMENSIONED TO FIT INSIDE
SCHEDULE 60 24" PIPE ffl 22.06 ACTUAL
INSIDE DIAMETER OF THE PIPE)
A COMBINED LENGTH OF 20'
WILL BE REQUIRED
NOT TO SCALE
REVISION A
23 MARCH 93
Figure 7. Vacuum-formed insulation.
58
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TABLE 15. SPECIFICATIONS FOR HYD RO G A S IF ICATI O N REACTOR
Parameter
Specification
Reactor diameter
Reaction section
Bed height
Feed entrance above distributor plate
Reactor area
Feed gas flow
Superficial velocity
Operating pressure
Operating temperature
0.15 m (6 in.)
3.2 m (10.5 It)
1.2 m (4 ft)
03 m (1 ft)
0.108 ra2
4.4 kmol/h
12.9 m3/h (7.6 cfm)
0.2 m/s (0.67 ft/s)
30 bar (441 psia)
800"C (1,472°F)
2"0
FREEBOARD SECTION
LOW ABRASIVE
REFRACTORY REQUIRED
THIS SECTION
EXIT PIPE
4' -6*
10*—6"
1000 "C 1832 °F INTERNA!
100 "C 212 °F EXTERNAL
PIPE AFTER HEATER II
910° C
204*C
1670° F INTERNAL
400° F EXTERNAL
REACTION SECTION
6"0
PLENUM SECTION
z-v
i
stepkan
SEPARATION
PLATS
1000° C 1832" F INTFHNAI
204° C
400° F EXTERNAL
1000° C 1832" F INTERPJAf
100° C 212° F EXTERNAL
2"0
PIPE AFTER HEATER I
HPR BORE CONFIGURATION
Figure 8. HPR vessel.
59
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valve at the bottom of the cyclone. The valve opens when sufficient weight of material enters
the dipleg. This technique is used in commercial applications.
63 HPR SOLIDS REMOVAL
Ash and bed materiaL will be removed from lock hoppers LH-833 and LH-835. These
will be insulated pressure vessels that are rated for the temperature of the ash and the system
pressure. The temperature of the ash will be less than that of the HPR by the time it reaches
the lock hopper. A stream of natural gas flows into the lock hopper to keep passages clear of
solids. The natural gas will cool the ash to some extent. Heat losses from the uninsulated
vessels will also result in low wall temperatures. Lock hopper valves are high temperature
industrial valves with an inner diameter of 25 mm (1 inch).
6.4 BIOMASS FEED SYSTEM
The solids feed system consists of a bulk materials area and a feed tank area. In the
bulk materials area, wood and a gettering agent are mixed together, while sand is stored
separately. The mixed solids are introduced into the day bin which empties into the lockhopper.
The sand is introduced separately into the lockhopper. At the bottom of the lockhopper, a
metering screw regulates the entry of the solids into the HPR vessel.
Biomass particle size and shape
The particle size of biomass feed affects the performance of the feed system and the
reaction time in a gasifier. The least dimension is the controlling factor in determining the
reaction rate. Smaller particles will react more quickly; however, the processing cost (in
commercial systems) increases with additional hardware and energy required for smaller
particles. Smaller particles are also subject to charring in the feed system and very small
particles tend to form plugs that clog feed systems.
Particle size affects the performance of the feed system. Uniformly sized particles feed
better than particles with a range of sizes. Cubic-shaped particles tend to clog less readily than
long strand-like particles. Therefore, particles that are produced by cutters or chippers tend to
clog less than particles produced by hammer mills. Hammer mills impact wood and produce a
particle with shattered fluffy ends that tend to stick together. A wood moisture content below
20 percent is required to prevent sticking in the lock hopper and screw feeder. For small-scale
systems, saw dust and wood chips are options that are consistent with the abilities of a feed
system. Smaller particle sizes will result in a more rapid reaction rate. Wood particles with their
least dimensions greater than sawdust can also be tested within the capabilities of a bench-scale
feed system.
Table 16 summarizes particle size dimensions for wood feeds. The smaller feed sizes
are considered for laboratory and bench scale-systems because they are compatible with the size
of the feed system and also provide faster reaction rates. Since small reactor systems will not
have the same bed height as commercial systems, it may be desirable to test smaller particle sizes
in these reactors.
60
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TABLE 16. PARTICLE SIZE OPTIONS FOR BIOMASS FEED SYSTEMS
Particle size (mm)
Linear diameter
Material Min. Max.
Small scale system
Sawdust, wood shop 0.05 to 2 2
Sawdust, cut 0.4 to 2 3
Wood flour 0.05 0.5
Wee chips 1.5 12 x 12
3 mm (1/8 in) Cut chips 3 3
Commercial system
Pulp chip 3 20 to 25
Large chip 12 to 20 25 to 50
Comments
Typical material from lumber yards
Uniform size should feed better
Too small and fluffy to feed well
Feeds well, prepare with modified chipper
Custom cut for laboratory reactor, simulates pulp
chip scale min. dimension
Industry standard for biomass energy systems
Larger size, possibly for 5,000,000 kg/day, lower
cost
Sawdust from a lumber mill was tested by Acurex Environmental in a 0.15-m cold flow
fluidized bed. The sawdust ranged in particle size (screen size) from 80 to 1,000 fim. Eighty
percent of the material was over 300 fim. This material did not flow well under all
circumstances, possibly because of higher than ideal moisture content. The material formed
large plugs when it was added to the cold flow reactor. Adding sand as a fluidizing media
allowed the sawdust to fluidize well. Some difficulty was exhibited when flowing through a
25-mm ball valve. Presumably drier more uniformly sized sawdust would flow more readily. The
best type of sawdust would be uniform in size and be free of small powdery material. Such
sawdust can be produced with a thin saw blade and flows without clogging. Special cut and size-
controlled sawdust should be used for a bench-scale system. Relying on the particle size
distribution and consistency of feed from lumber mill sawdust will be too risky.
Very fine material such as wood flour is unacceptable as a feedstock because of its
tendency to plug in a feed system. Wood flour might have a 50 nm particle size. This material
would also tend to char prematurely in the feed system.
Hand cutting can readily produce sufficient feed material for a 40-mm laboratory-scale
reactor. Three to 10-mm cubes would be a reasonable size range, given the reactor inner
diameter and the size of available sawdust. A 3-mm particle size will simulate the least
dimension of some commercial feeds. Larger cubes up to 10 mm could also be tested.
Producing 3-mm-particle size wood feed might be feasible for a 500 kg/day bench-scale system.
However, the reaction time will be longer than that of sawdust.
Experience has shown that thin chips (wee chips) can be produced by modifying a
commercial chipper. Moving the blades closer together will result in a chip as thin as 1.5 mm.
This chip can also be fed with a screw feeder.
61
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Commercial biomass to energy facilities uses a particle size referred to as a pulp chip.
Experience has shown that this type of particle can be successfully fed into 500,000 kg/day
gasification systems. For larger 5,000,000 kg/day systems, a larger particle size might be
considered; however, the effect on fluidization and reaction rate would need to be investigated
further.
Table 17 shows the specifications for the biomass feed system.
Alkali Getter Feed
Getter material is added in proportion to the expected alkali content of the biomass feed
which is estimated from the ash content and alkali fraction of the ash. Table 18 shows that an
TABLE 17. BIOMASS FEED SYSTEM SPECIFICATIONS
Parameter
Value
Feed materials
Sawdust bulk density
Sawdust particle density
Voidage
Maximum particle size
Particle minimum dimension
Sand bulk density
Sand particle size
Kaolin it e bulk density
Kaolinite particle size
Operating biomass feed
Design feed rate
Biomass
Sand
Kaolinite
Volumetric throughput
Top valve diameter
Bottom valve diameter
Lock hopper volume
Metering bin volume
Lock hopper diameter
Metering bin diameter
Vessel material
Number of metering screws
Metering screw diameter
Injection screw diameter
Initially clean white wood
Also tree trimmings and other waste materials
180 kg/m3
630 kg/m3
0.71
3 to 10 mm
1 to 5 mm
1400 kg/m3
0.3 mm
1200 kg/m3
0.1 mm
22.8 kg/h (50 lb/hr)
45.6 kg/h (100 lb/hr)
0.25 kg/h (0.55 lb/hr)
0.25 kg/h (0.55 lb/hr)
0.25 m /h (8.9 ft3/hr)
150 mm (6 inch)
150 mm (6 inch)
9.3 L (0.33 ft3)
• 84.9L (3 ft3)
150 mm (6 inch)
200 mm (8 inch)
Steel
50 mm (2 inch)
67 mm (2.63 inch)
62
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TABLE 18. ALKALI GETTER FLOWRATE
Parameter Value
Biomass dry feed (kg/h) 22.8
Ash content range (wt %) 05 to 6.6
Ash content (kg/h)
Maximum (design) 1.7
Minimum 0.11
Clean wood in PFD 0.17
Ash bulk density (kg/m3)
Design ash flowrate (m3/h)
Alkali content range (wt % of dry ash) 0.5 to 5
Alkali flowrate as K (g K/h)
Maximum 85
Minimum 0.55
Clean wood in PFD 1.7
Design alkali flow (mol/h) 2.2
Alkali getter Kaolinite
Composition Al202'2Si02
Alkali absorption (mole K/mole getter) 2 at 90% efficiency
Molecular weight (g/mol) 190
Design kaolinite feed (mol/h) 1.2
(1/h) 250
Bulk density (kg/m ) —1200
Volumetric flow (L/h) 0.2
alkali getter flowrate of 0.25 kg/h should be sufficient to capture the alkali in most wood
feedstocks.
Sand Feed
Ash, char, and bed material can either be removed from the bottom of the HPR or from
the ash overflow port at the top of the bed. If the HPR operates such that the bed height is
below the removal port, ash and bed material will be removed together from the bottom port.
If the HPR operates at maximum bed height, lighter ash and char may be removed from the top
port and sand can remain in the HPR for a longer period of time. The rate of sand feed will
be determined either by the amount of bed material removed from the HPR in order to remove
ash and char or by a predetermined replacement rate. If all ash removal is performed from the
bottom of the HPR, the estimates in Table 19 show the required sand feed rate for the HPR.
6£ PROCESS GAS SUPPLY
Process gases will be provided in tube trailers. Tube trailer gas consumption is discussed
in Section 2.
63
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TABLE 19. SAND FEED INTO HPR
Parameter
Value
Biomass feed rate (0% moisture)
Ash feed/removal rate
Bed removal rate
Sand volume
Sand mass
Sand removal rate
1.37 liter (0.9 m high)
22.9 kg/h
1.4 kg/h
6%/hr
4.9 kg
0.3 kg/h
6.6 FEED GAS HEATER
Acurex Environmental has developed preliminary design specifications for the electric
heater that maintains the HPR feed gas temperature at 800 °C. Stream 7, the simulated recycle
stream, exits the heat exchanger at 600°C and combines with steam, Stream 2, before entering
the heater. The heated stream then enters the HPR vessel directly.
The water heater needed to convert water to steam at 277°C must provide at least 9 kW
of power. However, the water heater should actually be sized at 15 kW to provide an
appropriate capacity factor.
"The temperature of the combined stream (stream 7 plus stream 2) which enters the
heater was calculated to be 525°C. The electric heater must heat the inlet gas from this
temperature to an outlet temperature of 1,000 °C. Based on the specific heat of the mixed
stream, the ideal required power outlet of the electric heater was calculated to be 20 kW. In
order to provide for rapid startup and to accommodate heat losses from the vessel and
associated piping, the heater should be sized for a capacity at least 50-percent greater than the
actual gas heating requirements. Thus, this heater should be sized for at least 30 kW capacity.
The expected process conditions are shown in Table 20.
The following equipment must be specified:
• Heating element assembly
• Pressure containment vessel
• Electrical feed-through connections
• Temperature sensing elements for process gas stream sensing
• Temperature sensing devices for the heating element surface
• Required controls, mounted in 0.5 m (19-inch) racks
An evaluation of the heating elements available suggests that the Kanthal SUPER
elements are the most appropriate, despite their cost, because they provide the following:
64
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TABLE 20. PROCESS CONDITIONS FOR ELECTRIC HEATER
Stream Description
Volumetric Gas Flow (kmol/h)
CO Nz HjO (steam)
Temperature
(°C)
Pressure
(bar)
Specific
heat Cp
(kJ/kg°C)a
Mass
flowrate
(kg/hr)
"Recycle" (Stream 7)
3.64
0.31
0.46
0.00
600
50
4.7
28.9
Steam (Stream 2)
0.00
0.00
0.00
0.72
277
50
22
12.9
Heater inlet (Stream 68)
3.64
0.31
0.46
0.72
525
50
5.4
41.8
Heater outlet (Stream 73)
3.64
0.31
0.46
0.72
1,000
50
5.4
41.8
' At constant pressure.
-------
• Smaller pressure vessel size for elements operating at element surface
temperatures higher than Al-Cr-Fe elements.
• Lower surface maintenance intervals. Periodically, an oxidation layer may
accumulate on the heater element surface, requiring venting. During this
procedure, air is run through the heater while it is turned off and the system is
not operating. It is not necessary for this air to be supplied at pressure, and it
should not come into contact with the reactor bed.
• Greater operating envelope capabilities for elements with significantly higher
surface temperature capabilities
Proposed Heater Vessel Configuration
The heater configuration is a typical shell and tube heat exchanger, with the heater
assembly substituted for the tube sheet and tubes. The heater vessel configuration and internal
layout are shown in Figure 9. The internal diameter is about 0.38 m (15 inches), providing an
active tube element length of 1.2 m (4 feet). The heating elements are in a hairpin
configuration. About 0.3 m (12 inches) of the heating element consists of a "cold length" to allow
for entry through the heater tube sheet. The vessel has a refractory lining 0.15 m (6 inches)
thick. The total outside diameter of the vessel is 0.76 m (30 inches), and the total length is
approximately 2.7 m (9 feet).
6.7 HOT GAS FILTER
The filter for the hot gas exiting the HPR operates at 50 bar and 800 °C. The filter
consists of one candle filter made of SiC (pall vitripore). The expected face velocity is 0.82 m/s
(2.7 ft/min). The cleaning frequency depends on the dust load and resistance, and should
average about once every 20 minutes. Figure 10 shows the filter vessel.
6.8 WATER SCRUBBER
A water scrubber was designed to remove particulate matter from the HPR effluent
(Table 21). The water scrubber shown in Figure 11 is designed to cool the HPR gas to the
boiling point of water at 30 bar. An alternate water scrubber was also designed to cool the
process gas down to ambient temperature.
6.9 ZINC OXIDE DESULFURIZATION SYSTEM
A desulfuriztion vessel was designed to capture H2S in the HPR gas stream. The
specifications for the desulfuriztion vessel are shown in Table 22. The vessel is shown in
Figure 12.
66
-------
COLD GAS BLEED
ELECTRICAL
FEEDTHROUGHS
HEATER TUBE
SHEET
COLD WIRING
SECTION
COLO-WOT
FUNCTION
(TYPICALLY 20
ELEMENTS)
CIRCULATION
BAFFLES
0 15"—16"
o
Ui
Figure 9. Heater assembly in pressure vessel.
67
-------
DUST COLLECTOR PORT
Figure 10. Hot gas filter.
68
-------
TABLE 21. WATER SCRUBBER CONFIGURATION
Parameter
Value
Inlet gas flowrate (kmol/h)
5.7
(kg/10
87.6
Inlet gas temperature (°C)
800
Inlet gas flow (m3/h)
14.4
Inlet gas H20 (kmol/h)
1.0
Exit gas flowrate (kmol/h)
4.7
(kg/h)
69.6
Exit gas temperature (°C)
60
Exit gas flow (m3/h)
4.5
Gas heat capacity (kJ/kg°C)
3
Steam heat of vaporization (kJ/kg)
1796
Heat transfer: gas to water (kW)
54
Heat transfer: steam to water (kW)
9
Total heat transfer to water (kW)
63
Cooling water flowrate (kg/s)
0.5 (8 gpm)
Design water flowrate (kg/s)
1.3 (20 gpm)
Cooling water boiling point (°C)
250
Heat transfer below boiling point (kW)
9.8
Heat exchanger length (m)
1.5
Number of tubes
19
Tube outer diameter (mm)
19
Inlet gas flow (m3/h)
0.88
Outlet gas flow (m3/h)
0.24
Inlet gas flow @ 250 °C (m/s)
1.05
Outlet gas flow (m/s)
0.29
69
-------
n
234°C (454°F)
30 bar (440 psia)
1.26 US (20 gpm)
PROCESS GAS OUT
27°C (80°F)
30 bar (440 psia)
207 Nm3(129 scfm)
PROCESS GAS IN
720°C (1328°F)
30 bar (440 psia)
26.8 m3/n (15.8 acfrn)
207 Nm3 (129 scfm)
Figure 11. Water scrubber system.
70
-------
TABLE 22. ZINC OXIDE DESULFURIZATION SYSTEM
Parameter Value
Biomass dry feed (kg/h) 22.8
Feed sulfur content (wt %) 0.16
Sulfur flow (kg /h) 0.036
(kmol /h) 0.0011
Gasjfier output (kmol/h) 5.7
Sulfur concentration (ppmv) 200
ZnO capacity S/ZnO (kgs/kg ZnO) 0.3
Operating lifetime (h) 350
Captured sulfur per charge (kg) 12.6
ZnO consumed per charge (kg) 42
Capacity factor 3
13 esigu ZnO (kg) 126
Zinc Oxide Granules ICI Catalyst 32-4
ZnO (%) 90
CaO(%) 2
A1203 (%) 8
Surface area (m /g) 25
Bulk density (kg/m ^ 1100
Diameter (mm) 3 to 5
ZnO bed volume (m3) 0.11 (4.0 ft3)
Space velocity (h"1) 1120
Operating temperature (°C) 400
Operating pressure (bar) 30
Gas flowrate (m3/h) 10.5
Bed diameter (m) 0.34 (1.13 ft3)
Bed area (m2) 0.09
Bed height (m) 1.2 (4.0 ft)
Superficial velocity (m/s) 0.032
Gas residence time (s) 37
MnO bed height (m) 0.3 (1 ft)
MnO granules Catalyst type to be determined
Design Temperature (°C) 600
Design Pressure (bar) 37 (550 psi)
71
-------
Figure 12. Zinc oxide desulfurizatlon vessel,
72
-------
SECTION 7
EQUIPMENT, SITE DEVELOPMENT, AND MATERIAL COST
Cost estimates were developed for the equipment, site development, and operating
materials for the Hynol project. Tables 23 through 25 show equipment cost estimates for the
HPR, SPR, and MSR systems. Table 26 shows cost estimates for site development. Tables 27
through 29 show the cost of expendable materials for HPR, SPR, and MSR testing.
73
-------
TABLE 23. HPR EQUIPMENT COST
Hynol HPR System Equipment Cost
Tag No.
Component
Pressure
(atm)
Description
Cost
•
R-101
Hydropyrolysis reactor
30
24", refractory lined
$52,440
T-805
Metering bin
30
24"
$10,000
SF-806
Screw feeder and motor
30
$10,000
LH-801
Lock hopper
30
$10,000
T-802
Pre-feed hopper
1
$2,000
T-803
Sand hopper
1
$500
SF-850
Metering screw and motor
30
$8,000
F-626
Natural gas filter
10
$500
C-627
CNG compressor skid
200
$60,000
T-421
Nitrogen buffer tank
30
$200
C-706
Air compressor skid
50
60 cfm @ 600 psig
$40,000
XX-804
Biomass chipper
1
$5,000
XX-805
Biomass conveyor
1
$5,000
T-051
C02 heater tank
1
$500
LH-834
Ash hopper top
30
$2,000
LH-835
Ash hopper bottom
30
$2,000
LH-833
Ash hopper bottom
30
$2,000
F-104
Hot gas filter
30
$30,720
H-102
Filter heater
30
$1,000
T-842
Nitrogen buffer tank
60
$1,000
H-843
Buffer tank heater
60
$500
F-521
Reverse osmosis filter
1
$1,000
T-513
Boiler feedwater tank
1
$500
T-559
Steam generator, 750 psi
50
$65,000
H-036
Recycle gas heater
30
$60,000
HX-038
Inter-heat exchanger
30
$15,000
B-037
Burner
30
$3,700
Total HPR equipment
$388,560
Instrumentation and controls
EPA ordered {$120,000)
$0
Instrumentation and controls
to be ordered
$40,000
V-839
Lock hopper valve, top
30
$800
V-840
Lock hopper valve, bottom
30
$800
Piping
$5,000
Tubing
$5,000
Subtotal
$440,160
Sales Tax
7.50%
$33,012
Shipping
5.00%
$22,008
Electrical Installation
$40,400
Contingency
20.00%
$99,036
HPR Structure
$99,060
Total HPR system
$733,676
74
-------
TABLE 24. SPR EQUIPMENT COST
Hynol SPR System Equipment Cost
Tag No.
Component
Pressure
(atm)
Description
Cost
-
f
R-201
Steam pyrolysis reactor
30
$100,000
C-201
Combustion air blower
1.3
$3,000
HX-206
HP steam heat exchanger
30
$5,000
HX-205
lnter-heat exchanger
30
$20,000
F-205
Sulfur removal bed
1
$2,000
F-206
Water scrubber
30
$2,000
Total SPR equipment
$132,000
Piping with insulation
$2,000
Tubing
$1,000
Fittings
$2,000
Instrumentation and controls
$30,000
Subtotal
$167,000
Sales Tax
7.50%
$12,525
Shipping
5.00%
$8,350
Mounting modifications
$10,000
Electrical installation
$5,000
Contingency
20.00%
$40,575
Total SPR system
$243,450
75
-------
TABLE 25. MSR EQUIPMENT COST
Hynol MSR System Equipment Cost
Tag No.
Component
Pressure
(atm)
Description
Cost
R-301
Methanol reactor
50
$110,000 CE-CERT buys
—
E-312
Evaporator
50
_
T-310
Steam drum
50
-
P-311
Cooling water pump
50
-
HX-309
Inter-heat exchanger
50
-
HX-313
Heat exchanger
50
_
T-314
Methanol separator
50
—
MSR system dismantling
$100,000
MSR system installation
$20,000
C-308
Circulation loop compressor
50
360 scfm, 100 psig
$10,000
C-304
Recycle gas compressor
50
90 scfm, 400 psig
$10,000
T-307
Knock out drum 2
50
$500
HX-306
Heat exchanger
30
$3,000
F-305
Clean up bed
30
$2,000
T-303
Knock out drum 1
30
$500
HX-302
Distillation heat exchanger
30
$5,000
P-302
Bottoms pump
1
$500
D-315
Distillation column
1
$5,000
HX-317
Heat exchanger
5
$3,000
T-TBD
Condensate drum
5
$500
P-319
Reflux pump
1
$1,000
T-320
Methanol product drum
1
$500
T-321
Methanol storage tank
1
2000 gal
$25,000
MSR Equipment
$66,500
Instrumentation
$40,000
Tubing and fittings
$5,000
Gas clean up structure
$54,500
Equipment subtotal
$166,000
Sales Tax
7.50%
$12,450
Shipping
5.00%
$8,300
Electrical installation
$10,000
Contingency
20.00%
$39,350
Total MSR system
$356,100
76
-------
TABLE 26. SITE DEVELOPMENT COST ESTIMATE
jca m
i mamsr mue;
fQyjt HTMOL aw Wartr (Qn^ng, P«*1r*, €«~>«*(«, »>4 Un4aeq£igl
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LAeCfl
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TAX
FREIGHT
TOTAL
1
mi.ioa ©oo
Sfco atoarlng. 200 H.P, titan and bush rtls. iitfit
zsa
ACRE
j.iot.ao
2
8.000
30.30
99.7%
111£%
120.0%
0.00
I £39.73
3^S5.84
194.70
5, roo.36
2
021.144.0020
Stripping topsci andiaoefcpJb, a«rnfr town, 200 H.p. dozer. (food eandiilQM
4,074.0?
cv.
0.37
2
0.003
23S&
98.7%
1114m.
12*h0%
0.00
8BS.26
1,790-41
89.52
2,77519
3
022.242.4020
Excavating, fcult, 200 H.P. doror, i*wn rM», 5ft' haul, txxmwn ©firth
6,000.01
C.Y.
O.BO
7
0.00?
?3i0
oaTt.
1ltJB%
120.0%
000
2.739.37
M7B.41
273.82
B.49! 70
4
027.203.42KI
Dacliftl, StatdurRl, 200 H.P. dorar, fromneaMiog sfodcpio, isChBitctfwnao
0,614.0%
122 6%
120.0%
938.1?
963.27
io.m
7923
l,iKI7 i>0
11
033.129.0040
flearV mhr eortoieM, 3000 pid
am
c.r.
se.ia
102J%
1102%
120.0%
2JSG9J!4
0.00
0.00
214.44
aaiiGs
12
PlarAng emoiei», wtsaUnQ, slab an gpradB cwOf fP ttfck. dtoct elUUl
3?.?1
ex.
0.41
6
. o.CM a
25.19
102L3%
110,2%
120.0%
0.00
408 44
1913
0.06
429.53
is
633.4S4.dt5a
Finishing alah surface, breem Anliih
lr2Qfi.no
SJ.
0.00
1
0.012
sills
102.3%
1T62%
120.0%
0.00
62900
BO. IB
4A\
mm
14
033.104.0000
Curing eoenla «th afrauod morr^rans niifcoconpaund
12^0
C.8.F.
2.10
2
0.064
W-85
102.3%
1102*
120.0*
30-51
75.71
0.00
2,76
i n.m
15.
03U54.CDIO
Parma fei p<*», a^lfHReni louftdaliWM, 1 use, 18* W{Ji
QS&SSt
SfCA
1.80
0.22
•
0,060
33.11
11447%
122 6%
120,0%
2459.05
13.98Z43
»7.57
209.92
16.616,07
IS
G32.107.0600
RoMoicing in f*#ce, As is Gi.60, «tab on gr*&, 2 mala. I2KJ LF. of 15
8,70
TON
61050
4
3.47S
40.00
<24S%
120J%
12047%
9,113.10
6.797.45
0.00
504.33
12,494 9?
17
033.126.0Dia
Ready mtaearwrote, 3030 f«J
107.08
C.Y,
se.io
10217%
1f0^%
137.0%
7^81.78
Q.00
0.00
608.00
1,000.75
19
033,172.469)
Placingconoraie, vbraUng, slab an grade mt* fi*INbh. droM cfcu«e
107.06
C.Y,
0X1
0
o.Ma
sfl.te
<022%
1W2%
1205%
0.00
M5&.99
M.33
272
1.21701
1ft
(B3.4S4.61rB
flnhHwo il*!) mtiacA, broom Inbft
2,029.00
3JF,
006
t
0.012
DI-65
1023%
1102%
120.0%
0.00
1,452.02
204,02
1020
1.S97.14
20
033.134.03Oft
Coring concrete nth sprauMf oMnrivaria curing cm^*mnd
7B7B
C.S.F.
7.10
7
0.094
?6.BS
1023%
1102%
1»0%
77.62
175 IB
0.00
6.40
759.97
2!
023.723.00 Id
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3ft0 00
L.F.
0.10
0A1
2
0.015
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17.72
22
020.729 6106
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190.0%
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25
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40 J9
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4.17
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0O99
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111.6%
120.0%
ooo
419.72
isa.ss>
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S77.70
26
028.952.0009
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5.71
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s
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99.7%
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4,Qfi1.tlfi
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325.00
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007
7
0.018
26 MS
98.7%
m.6%
120.0%
515.22
B.B22..20
0.00
42.51
9,479 93
35
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801.00
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0004
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aa.7%
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10.070168
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73307
897.49
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£.069.24
784ffi
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523.00
7,893.13
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02 2.2/4.01 Ctf
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202.07
1
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99.7%
11t«*
120.0%
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545.09
ai
94.14
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39
029.308.0S00
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f.CKM.77
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79.19
33A3
£59.90
49
028.303.1300
Fortce, brKes
10.00
EACH
13.58
5i7
4
0.100
29.01
99.7%
nie%
120.0%
teotw
I5&41
05.99
1BA7
3&84M
41
«'Sck%
100.0%
100.0%
0.00
000
coo
0.00
0.90
100.0%
1000*
100 0%
0.00
0.00
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0.00
0.00
100.0*
100.0%
100.0%
o.oo
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006
0.00
0.00
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1SOO*
100.0%
0.00
000
0.00
0.00
0.00
100.0*
1000%
106.0*
000
0.00
0.00
0.66
0.00
100 0%
1000%
100.0%
0.00
000
000
0,00
0.00
100.0%
100 0%
100,0%
o.oo
o.oo
0.00
aoo
0.00
100.0%
100.0%
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0.00
0.00
0.00
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O.OO
100.0%
100 0*
100.0%
o.oo
000
o.oo
000
0.00
total mem this sheet - eii.334.s2
TOTAL FROM PfECEEOfNQ SHEETS. >
-------
TABLE 27. HPR OPERATION MATERIALS
OPERATING COSTS
HPR
Weekly operating costs
No.
Description
Quantity
Cost per unit
Total cost
2.5
Utilities
Electricity (kWh)
10,253
0.1 S/kWh
1,025
Natural gas (scf)
120,960
0.7 $/100 scf
847
Water (gal)
1,325
0.02 5/gal
26
Total for one week
1,898
2.2
Feedstock
Sawdust (lb)
4,800
0.1 Mb
480
Total for one week
480
2.3
Gases
HYDROGEN:
H2 trailer rent
2
1000 $/wk
2,000
Trailer mileage
SO
1.8 #/mi
90
Hydrogen gas (100 scf}
2,346
4.25 5/100 scf
9,971
CO;
CO trailer rent
1
1000 $/wk
1,000
Trailer mileage
3,200
1.8 $/mi
5,760
Carbon monoxide gas (100 scf)
171
6 $/100 scf
1,026
NITROGEN:
N2 trailer rent
1
1000 S/wk
1,000
Trailer mileage
50
1.8 $/ml
90
Nitrogen gas (TOO scf)
130
1.75 S/100 scf
228
Nitrogen - startup, trailer rent
1
1000 $/wk
1,000
Trailer mileage
50
1.8 $/mi
90
Nitrogen - startup gas (100 scf)
720
1.75 $/100 scf
1,260
Nitrogen 6 packs (100 scfl
4
2.5 $/100 scf
10
Nitrogen 6 pack demurrage
1
9 $/6-pack
9
C02:
C02 bottled gas CtOO scf)
325
10 S/100 scf
3,250
C02 bottle demurrage
135
2 S/bottle
270
Total for a one-week period
27,053
Total operating costs for one week
$29,431
Number of one week periods
4
Total weekly operating costs
§117,726
78
-------
TABLE 28. SPR OPERATION MATERIALS
OPERATING COSTS
SPR
Weekly operating costs
No.
Description
Quantity
Cost per unit
Total cost
7.5
Utilities
Electricity (kWh)
10,253
0.1 $/kWh
1,025
Natural gas (scf)
242,000
0.7 $/100 scf
1,694
Water (gal)
1,325
0.02 $/gal
26
Total for one week
2,746
7.2
Feedstock
Sawdust (lb)
4,800
0.1 $/lb
480
Total for one week
480
7,3
Gases
HYDROGEN;
H2 trailer rent
2
1000 $/wk
2,000
Trailer mileage
50
1.8 $/mi
90
Hydrogen gas (100 scf)
2,346
4.25 $/100 scf
9,971
CO;
CO trailer rent
1
1000 $/wk
1,000
Trailer mileage
3,200
1.8 $/mi
5,760
Carbon monoxide gas (100 scf)
171
6 $/100 scf
1,026
NITROGEN:
v-,.
N2 trailer rent
1
1000 $/wk
1,000
Trailer mileage
50
1.8 $/mi
90
Nitrogen gas (100 scf!
130
1.75 S/100 scf
228
Nitrogen - startup, trailer rent
1
1000 $/wk
1,000
Trailer mileage
50
1.8 $/mi
90
Nitrogen - startup gas (100 scf)
720
1.75 $/100 scf
1,260
Nitrogen 6 packs (100 scf)
4
2.5 $/100 scf
10
Nitrogen 6 pack demurrage
1
9 $/6-pack
9
C02:
C02 bottled gas (100 scf)
325
10 5/100 scf
3,250
C02 bottle demurrage
135
2 $/bottte
270
Total for a one-week period
27,053
Total operating costs for one week
$30,279
Number of one week periods
3
Total weekly operating costs
$90,836
79
-------
TABLE 29. MSR OPERATION MATERIALS
OPERATING COSTS
MSR
Weekly operating costs
No.
Description
Quantity
Cost per unit
Total cost
84
Utilities
Electricity (kWh)
5,000
0.1 $/kWh
500
Natural gas (scf)
242,000
0.7 $/100 scf
1,694
Water (gal}
1,325
0.02 $/ga!
26
Total for one week
2,220
8.2
Feedstock
Sawdust (lb)
4,800 ,
0.1 $/lb
480
Total for one week
480
8.3
Gases
HYDROGEN;
H2 trailer rent
0
1000 $/wk
0
Trailer mileage
0
1.8 $/mi
0
Hydrogen gas (100 scf)
0
4.25 $/100 scf
0
CO:
CO trailer rent
0
1000 $/wk
0
Trailer mileage
0
1.8 $/mi
0
Carbon monoxide gas (100 scf)
0
6 $/100 scf
0
NITROGEN:
N2 trailer rent
0
1000 $/wk
0
Trailer mileage
0
1.8 $/mi
0
Nitrogen gas (100 scf)
0
1.75 $/100 scf
0
Nitrogen - startup, trailer rent
0
1000 $/wk
0
-
Trailer mileage
0
1.8 $/mi
0
Nitrogen - startup gas (100 scf)
0
1.75 $/100 scf
0
Nitrogen 6 packs (100 scf)
200
2.5 $/100 scf
500
Nitrogen 6 pack demurrage
1
9 S/6-pack
9
C02:
C02 bottled gas (100 scf)
0
10 5/100 scf
0
C02 bottle demurrage
0
2 $/bottle
0
Total for a one-week period
508
Total operating costs for one week
$3,209-
Number of one week periods
2
Total weekly operating costs
$6,419
80
-------
SECTION 8
PROJECT SCHEDULE
Figure 13 shows the project schedule corresponding to the tasks and major milestones
in the Work Breakdown Schedule. The contract with EPA will start in August, while activities
with funding from CEC and the SCAQMD will be start at a slower pace prior to this date.
During the first 6 months of 1995, we expect to continue with site development activities such
as completing the site plan and soliciting bids for construction work. Site development and HPR
system procurement will take place during the first year of the project. The HPR/SPR structure
will be installed with the HPR and biomass feed system which will be followed by the operation
of the HPR on clean white wood. Testing of the performance of the hot gas clean up system will
also take place at this time. The SPR will be delivered after HPR testing and installed shortly
afterwards. The compressors and associated equipment for the MSR system will be procured
while the reactor is being shipped. After SPR testing is completed, the MSR, compressors, and
fuel tank will be installed.
The project schedule allows for the completion of the HPR, SPR, and MSR systems in
the first 2 years of the project. Additional operation of the integrated system with alternate
feedstocks can be completed in the third year. Some alternative feedstocks will also be tested
as part of the HPR operation in Task 2.
For Phase HI, in the third year of the project, we plan to perform additional testing with
wood feedstocks and alternate feedstocks. Such waste might include tree trimmings and wooden
palates. The composition of these wastes would consist of a higher alkali content, but sulfur and
chlorine content should not be sufficiently high that new gas clean up systems will be required.
Alternate gas clean up systems can also be tested in the third-year option period. Both a hot
gas cleaning system and a water scrubber system have been considered for particulate removal
for the Hynol system. Alternate clean up systems can be tested in the third year of the program.
81
-------
00
NJ
Project Schedule - Biomass to Methanol Using the HYNOL Process
EPA
Ref
EPA
Opl
CEC
Ref
AEC
Task
Description
94
1995
1 V9A
JS9?
199 8
D
J F
M
A
M
J
1
s
0
N
D
J F
M
A
M
J
J
A
s
0
N
D
J
F
M
A
M J
J
A
s
0
N
D
J F M
A M J
0
CO
Completed Tasks
1
CI
Site S dec lion
4
C .2
Design Water Scrubber
7
C3
Desicn Zinc Oxide Svslem
10
©.«
Management and Reporting
1.A
0,1
Monthly Progress Repents
v> y
\7
<7
C
7
7 K7
7
57
V
7
*7
57
*7
7 y
7
7
7
7 X7
V y
7
V
7
7 57 y
<7 V :
0.2
Interim Report* lo ErA
7
v :
IB
03
CEC Annual Financial Hud Economic Benefits Statement
V
1.C
0A
Submission of CEC Invoices
^ :
(7
7
7
7
7:
<7
7
2.1.A
0,5
Outline CEC final Report
<7
2. LB
0.6
Draft CEC Final Rcoon
7
2.1.C
0.7
Complete CEC Finn! Report
V
U2
O.ft
y
2J
9.9
TViMrminsl'iftn nfCRfl Pmied Perfnrmanrr
>7
fltn
PPA Fmaf Rrpmt
• ^
2
5
0
11
1.0
H P R System Construction Schedule
Li
Create Industrial Review Group ORG)
—
u
Identify Alkali Sor bents
u
Final Design
1.4
Generate Equipment Specifications
=57
L5
Update QAfend:Tcsi Plans fbrHPR
1.6
Permitting
K~
=5
7
1.7
Bid Documents • Site Development
Je=
IS
Bid Evaluation and Commitment - Site Development
1.9
Grading
A
:
1.10
Underground Utilities
££=57
1.11
Concrete Foundations
4?^
57
1.12
Curbs and Gutters
L
fj
1.13
Asphalt Paving and Site Surface Cover
tsSJ
1,14
Fencing
7
1.15
Bid Documents - Equipment
S=
7
1.1*
Bid Evaiuatioo and Commitment - Equipment
1.17
Fabricate Vessels and Equipment
1.18
Assemble Vessels and Structures
1.W
Install H PR Structure
Zs=V ¦
tM
Install Process Equipment
Z!r
z=sj ;
8
141
Provide Analytical Capability lo Monitor Effluent
5
142
Mechanical and Plumbing
143
Electrical and Instrumentation
144
Landscaping
Z57
145
Pre - Commissioning
126
Report Pre - Commissioning Results
:
Figure 13. Project schedule.
-------
Project Schedule - Biomass to Methanol Using the HYNOL Process
EPA
Ref
EPA
Opt
CEC
Ref
AEC
Task
Description
94
1995
I 99 S
1997
1998
D
J
F
M
A
M
J
J
A
s
o
N
D
J
F
M
A
M
J : J : A
SO
N
D
J
V
M
A
M
J
J
A
S
O
N :D
J
r
M
A
M
J
9
0
12
10
HPR SvEtem Operation Schedule
11
Train Operator*
£s*7
S
2.2
Procure Solid Feedstocks
h=£? :
23
Procure Feed Oases
h=*7 '¦
9
2,4
Perform Start -mo Tests
V^7
2.5
Operate Hydrogisiftcr
!%7
A
=57
2.6
Analyze Operating Data
2,7
Perform Safety Reviews and Inspections
A
10
1
2.8
EPA Option 1 Review
7
«
0
13
3,8
S PR Svstem Dcsisn Schedule
3.I
Prepare Process Flow Diagram
-------
Project Schedule - Biomass to Methanol Using the IIYNOL Process
EPA
EPA
Opt
CEC
ReF
AEC
Task
Description
94
1995
1996
J 997
1998
D
J
F
M
A
M
J
1
A
S
O
N
r»
J
FjMjA-M; J
J A
S O
N
0
J F M
A
M
J i J
A
S
o
N
D
J
F M
A
M
1
16
2
1.6
6.0
M S R System Construe lion Schedule
6.1
Procare Methanol Synthesis System
6.2
Arrange for Shipping of Methanol Synthesis System
2S~~r~X7 :
63
Ship Methanol Synthesis System
6,4
Install Methanol Synthesis System
£=5
7
6.5
Fabricate EcruiDmcnl
6.6
Install Process Equipment and Fiiel Tank
Zs=57 ;
6.7
Mechanics! and Plumbing
"
6.8
Electrical and lasriumeotaiien
6.9
Pre - Commissioning
£s57
12
I
1.7
7.0
S P R System Operation Schedule
7.1
Train Operators
4V
7.2
Procure Solid Feedstocks
£S=!
7
7.3
Procure Feed Gases
7
7A
Perform Slut • up Testa, & f*
i
S=5
1
13
7.5
Operate HydroRasificr and S P R
A
^. y
7.6
Arialva and Report Opcr&Ung, Data
^7
7.7
Perform Safety Renews end Inspections
>
i
15
2
7.8
EPA Option 2 Review
17
IJ8
8.0
Integrated System Opera lion Schedule
R.I
Train Operators
8.2
Procure Solid Feedstocks
=£7
BJ
Perform Slart - up Tests
^7
8.4
Operate Integrated System on Clean Wood
£$=
—ty
8.5
Analyze and Report Operating Data
8.6
Perform Safety Reviews md Inspections
'A
A
IB
19
3
8.7
EPA Option 3 Review
17
8.8
Operate Integrated System on Military Waste
4
9.0
Additional Tasks
20
9.1
Install and Ten Hot Gas Cleanup System
21
22
s
9*2
EPA Option 5 Review
-------
APPENDIX A
SUPPLEMENTAL INFORMATION
• Flow Sheet for Integrated Hynol System A-2
• Flow Sheet for HPR System A-5
• Process Flow Diagram for HPR System A-11
• Piping and Instrumentation Diagram for HPR System A-13
• Line Designation List for HPR System A-18
• MSDS for Methanol ; A-22
• OSHA Requirements for Non-coded Vessels . A-26
)
• City of Riverside, Planning Department Fee Schedule A-28
• Bourns Facility Layout A-30
• CE-CERT Site Topographical Map A-31
• Specifications for Site Development A-32
• California Code of Regulations A-53
A-l
-------
HYNPFD3.XLS
8/31/95
REVISION 3
Stream #
Properties
Q, kg/h
Normal m3/h
Actual m3/h
MW
Enlhal. icai/h
T, "C
P, aim
Components:
H2
CH4
CO
C02
H20
02
N2 "
HIS
CH30H
TOTAL
Elements:
H
C
O
N
S
Total elements
Inerts (kg/h)
Enthalpy:
Based o 50 Ibs/hr dry wood. Flowsheet D, 9/8/94
. j„d|cl[ei calculated value) ; same as 65 1 +2+3+4+S+6+7
1
2
3
4
5
6
7
SUM OF INPUTS
BIOMASS
STEAM
KAOLIN1TE
SAND
N2 Makeup gas
CII4 to IIPR
urn In, post!IX
TOHPR
25.8
—
—
—
—
24.85
-"=;l|j:50.6S
—
_
r-
—
—
—
—
—
—
—
\i,.';A7.S20
18.00
190.00
—
28.00
16.00
—
-40,077
-15,981
—
_
0
0
-35,255
-91,313
25
268
150
150
25
150
88R
30
30 ¦
30
30
30
30
30
30
kmol/hr
wt %
kmol/hr mole %
kmol/hf wt %
kmol/hr wt %
kmol/hr mole %
kmol/hr mole %
kmol/hr
mole %
kmol/hr
mole %
_
—
—
—
2.93
76.69
2J>3
76.6900
—
—
—
—
¦ —
' 0.58
15.28
0.J8
15.2800
_
—
_
_
—
—
0.15'
3.80
0.15
3.8000
—
—
—
_
—
0.03
1.22
0.05
(.2200
0.17 1
1.80
'^fl00.00
—
- .
0.0019
0 20
0.00 ,
0.0500
—
-
-
-
-
—
0.05
1.39
0.05
1.3900
_
_ ,
0,06
1.57
0.06
1.5700
-
-
—
—
—
3.82
100.15
3.82
100.00
1.69:
6.60
_
it 45
87.17
10.13
77.2520
' 0.98'
4S.81
—
__
—
—
—
0.84
8.63
1.82'
13.8813
46.35
g:S;icmwo!
—
_
_
—
0.30
3.10
1.05
7.9877
0.0.
o;42
_
—-
— .
—
o.u
1.10
0.11
0.8692
,0.00
0.16
—
—
—
_
—
* —
—
0.00
0.0098
99.34
—
—
—
—
9.69
100.00
13.12
100,00
•S-Vb:i'7l
0.66
_
_
—
_
_
0.17
adjusted I AN/VP dH = m*Cp*dT dH » in*Cp»dT JANaF JANAF JANAF 1+2+3+4+5+6+7
for moisture
-------
HYNPFD3.XLS
8/31/95
REVISION 3 ash + residual Carbon . 2+6 + 7
Stream #
92
9
10
s
67
'
73,
44
IS
Properties
HPR OUTLET
Char >uli - HPR
Ash-F104
F-205 out
CH4 to cleanup
HPR gas Inlet
SPR exit
Post 1IX-205
Q, kg/h
' 74.71
1.68
—
74.67
12.90
24,85
118.53
00
ut
VW :
Normal m3/h
117 89
—
¦—
117.86
19.30
' 91,77
"* 246.85 ,
' " 246,85 _
Actual m3/h
14.42
—
, _
14.41
0.66
11,22
35.82
26.38
MW
15.21
12.01
—
15.20
16.04
- 6.50*
-•= 11.52
- -11.52
Enihal. kcal/h
-91,736
422.7
—
-91.736
—
-51,236
-89,878
T, aC
800
800
800
800
25
800
1000
664
P, aim
30
30
30
30
30
30
30
30
Components:
kmol/hr mole %
kg/hr wt 56
kmol/hr mole %
kmol/hr mole %
kmol/hr
mole %
kmol/hr mole 96
kmol/hr mole %
kmofhr mole %
H2
• 1.84
37.44
—
_
1.84:
37.44
—
.':;;2.93
76.69
6.03
58.65
6.03 58.65
CH4
19.48
r-
_
0.95
19.48
'Sid's?
100.00
0.58
15,28
0.34
3.26
0.34 3.26
CO
;S:asis;
13.42
—
—
i'V 0.66:
13.43
—
¦ :'t;.;0,15
.3.80
2.17
21.09
2.17 21.09
C02
0.38
7.72
_
—
' ;.0.38
7.72
—
:;,;:;.o!o5
1.22
0J0
2,87
0.30 2.87
1120
A1
'-vofil
19.76
—
—
-,0.;97.j
19.76
—
0.00
'ft M
0.05
1.35
13.10
1.35 13.10
U»
N2
2.16
o.u
2.16
ll.w .... .
0.05
1.39
0.11
1.03
0.11 1.03
H2S
V 0.00
0 03
_
_
—
—
o.oo
_
, —
—
_
CH30H
—
—
>
—
„
U 06
1,57
—
—
— —
TOTAL
4.91 100.00
—
—
4.91 [,;:i60.pO
0.80
100.00
3 82 100.00
10.29 100,00
10.29 100.00
Elements:
H
9.45
67.27
— —
—
9.45
67.27
3.22
80.00
8.4!
87.17
16.10 -
69.34
16.10 69.34
C
2.00
14.21
1.51 100,00
—
2 00
14.21
0.80
20.00
0.84 •
8.63
2.80
12.06
2.80 12.06
O .
2 39
17.00
— —
— .
2.39
17.01
* —
' —
0.30
3,10
4.11
17,69
4.11 17.69
N
0.21
1.51
_ _
—
0.21
1.51
' ™
—
0.11
1.10
0.21
0.91
; 0.21 0.91
S
0.00
0.01
_ _
_
_
* _
—
0.00
0.00
0.00
0.00
0.00 0,00
Total elements
14.05 100.00
1.51 100.00
_L 1
14.04 100.00
4.02
100.00
9.69 100.00
23,22 100.00
23.22 100.00
Inerts (kg/h)
—
0.17
—
—
Enthalpy: 1+2+3+4+5+6 Hydrocirb Hydrocarb 60+6? JANAF 2+6+7
ash: h - -223 kcal/kg
C: h = 267.5 kcal/kg
-------
HYNPFD3.XLS
8/31/95
REVISION 3
Stream H
Properties
Q, kg/h
Normal m3/h
Actual m3/h
MW
Emhal. kcalAi
T, *C
P, M
Components:
H2
CH4
CO
COT
H20
02
N2
H2S
CH30H
TOTAL
Elements:
H
C
O
N
S
Total elements
Inerts (kg/h)
Enthalpy:
Composition data
21
27
30
31
33
25
49
51
Post-HX to MSR
MSR out
Com), out
MSR Loop
Pre-IlX Inlet
Purge
Distillate H20
Methanol
118.53
343.0
211,5?
24623, ,
24.85
0,52
19.43
51.96
246.85
1,077.13
1,016 65
921.59
' 91.77
1.92
. —
9.09
70.11
36.92
, 33.47
3.38
0.07
V- ~
11.52
11.97
6.50
6.50
6.50
6.50
, 18,00 , '
-711,679
-30,520
30
260
50
50
50
50
50
25
30
30
30
30
30
30
1
1
kmol'hr mole %
krnoi/hr mole 36
kmol/hr mole %
kmol/hr mole %
kmol/hr tnole%
kmol/hr mole %
kiiroiflir mole %
kmol/hr mole %
6 03
58.65
31.56
65.64
32.04;
76.69
' 29.05.;
76.69
2.93
76.69
0.06:
76.69
—
_
f'
—
0 34
3.26
" 3.58
7.45
6J8
15.28
5.79
15.28
0.58
15.28
0.01
15.28
—
—
—
2 17
21,09
2.55
5.31
• 1.59
3.80
1.44;
3.80
0.15
3.80
0.00
3.80
—
_
' " —
—
010
2.87
5.93
12.34
0.5t'
1.22
0.46;
1.22
0.05
1.22
0.00
1.22
—
—
—
1 33
13.10
1,17
2.43
0.02;
0.05
0.02^
0.05
0.00
0.05
O.OO
0.05
1.08
100.00
, —
—
0.11
1.03
1.13
2.36
0.58.
1.39
0.53;
1.39
0.05
1.39
0.00;
1.39
-
—
2.15
4.47
0.66
1.57
0.59'
1.57
0.06
1.57
O.OO
1.57
1.62
100.00
10 29 lqojop;
48.09 100.00
41.78
100.00
37.88 100.00
3,82306.00
0.08 100.00
1.08
100.00
1.62
100,00
16.10
69.34
88.39
72.09
92.29
87.17
83.67
87.17
8.45
87,17
0.18.
87.17
2,16
66.67
; 6,49 (
66,67
2.S0
12.06
14.22 _
11,60
' 9.14
, 8.63
- 8,28"
8,63
' 0.84
-8.63
0.02
8.63
O.OO
' 0 00
1,62 :
16.67
4.11
17.69
17.74
14,47
3.28
3.10
2.98"
3.10
'• 0.30
•3. to
0,01
3,10
' 1.08
33.33
- l,6Z'
16.67
0.21
0.91
2.27
1.85
LI6
1.10
- 1,05
1,10
0.11 '
' 1.10
0.00
1.10
0.00
*' 0.00
.0.00
0.06
O.OO
0.00
0,00
0.00
000
0.00
• 0.00
0.00
' 0,00'
0,00
0,00'
000
0.00
0.00
- -0.005
0,00
23.22 100.00
122.62 100.00
105.87
100.00
- 95,98 100.00
9.69 100 00
0.20 100.00
¦ 3.24
100.00
9.73
100.00
JANAF
-------
Hynol Actual HPR System
5/4/94 Based on •, 50 Ibs/hr dry wood, from Y, Dsmg/M. Steinberg mono (8-3-93), CASE 1; scaJing factor = 0.238
REVISION 7 indicate! e»1cul»ledv«luts • • tame as 65 1+2+344+5+6-+7
Stream #
1
2
3
4
S
6
7
SUM OF INPUTS
Properties
GREENWASTE
STEAM
KAOLINITE
SAND
N2 Makeup gas
"Recycle" CH4
HPR in, poslHX
TO HPR
Q.kg/h
25.800
5.26
2.70
030""^
' W3 *'
547 ¦>
4C01
^ 80,47 '-S.-
Normal m3/h
...
7.01
...
—
""" 1.06
< » tn "
92.23 ~ -
-
Actual rn3/h
, 0 036
' 0,41"
0.0023
0.0001
• ,„** 404 „' -
" 0.26
, ?tr »
--
MWy
7.528
18.00
190.00
...
28.00
16.05
' - 1041 /
~
Emhal. kcal/h
-34201
•16.532
-380.84
-36.75
0
-5778
-40,893
-91393
t.*c
150
235
150
150
25
25
600
P, aim
30
30
30
30
30
30
30
30
Components:
kmol/hi wi %
kmol/hr mole %
kmol/hr wt %
kmol/hr wt %
kmol/hr mole %
kmol/hr mole %
kmol/hr mole %
kmol/hr mole %
H2
_
—
...
...
--
—
2 93 76 24
2 93 62.7250
CH4
...
...
0.32- ¦ 100.00
0 32 6 8933
CO
—
...
...
...
—
' 028 rf2S
0.28 5.9942
C02
—
—
--
'< 0.53 '*'13.87 '
0.53 114104
H20
0.17 11.80
...
...
o * ***** Un*
046 9 8952
02
...
...
...
—
—
— 0.0000
N2
...
...
0,04 * 100.00
_
' o w "Vso
0.14 3.0819
H2S
—
...
...
...
, ' N -
-- 0.0000
CH30II
....
...
...
—
— 0.0000
TOTAL
...
...
..
" 0 04 - 100,00
0.32 * 100.00
3 84 * fooloo
4 67 100.00
Elements:
H
1.69 6.60
0 58 66 67
—
--
J.29 80.00
5,86' 71*30
9 42 to 2293
C
0,98 45.81
—
...
—
032 20.00
081 P.89
2,12 14.9071
O
0.75 46.35
MS iiiil
...
—
'—'J" " -1
¦ 1.35--- '-IMS
'' 2.39 -16.7755
N
¦ 0,01 0.42
...
009 } 00,00
0.2O " 2.43
' 030 ' 2.0791
S
0,00 0.16
—
"0.00 0.QCW1
Total elements
3.43 99.34
.** .0,88. ;.;*i 100.00.
...
...
0 09 100 00
1.61 > 100.00
' 8 22 , ,|£X).00
14.22 I0f».0i:i
Incuts (kgjh)
0.17 0.66
—
2.700 "
0.296
—
—
3.17
Enthalpy:
'adjusted
for moisture
JANAF
dH = m*Cp*dT
dH = m*Cp*dT
JANAF
JANAF
JANAF
includes steam
enthalpy =
1+3+4+5~6+73
-------
Hynol Actual HPR System
5/4/94
kao'iniic + 5*md +
Not shown cm process
REVISION 7
60+57-10
ash + residual Carbon
flow diagram
some as 8
Stream #
8
9
10
12
46
60
61
62
Properties
Posl-F104
Char ash • HPR
Ash-F104
cmtoSPR
High-P N2
HPR OUTLET
HPR out-postHX
H2 In
Q.kg/h
, 87,45
; i-W ''
—
9.24
1,514
, '74.55if'"2
87.45
5-92
Normal m3/h
* 136.90
~
—
- 13 83
1,304
,,117,60.; _ ,
'' - 136 90 ?
A, 70.32
Actual m3/h
15.49
...
* 01«.
42.5
14,38
t ' il.44\/'?
2,39
MW
, 15.33
12.01
...
16.04'
28.00
,15.21
15.33- iJt
2.02
Enthal. kcal/h
-110,801
99
0
-10,330
99,909
-91,492
-124269
0
T, °C
720
SCO .
800
25
288
800
460
25
P, aim
30
30
30
86
61
30
30
30
Component'.
kmol/hr molt %
kg/hr wi %
kmoVhr mole %
kjno'.l'.r mole %
kmol/hr mole %
kmol/hr mole %
kmoi/hr mole %
kmol/hr mole %
m
1.83 32-16
—
...
, , —
¦ 1,83 37.44
1.83 32.16
2,93 100.00
cm
1.76 30.82
...
0.5S 100.00
0,95 19.48
1.76 30.82
CO
0.66 11.53
...
...
- 0 66 13.42
0.66 1133
—
CO!
0.38 6.63
—
...
_
- 0,38 7.72
0.38 6.63
—
H20
0.97 ' 16.97
—
...
" 0,97 19.76
0.97 16.97
...
02
0.00 0.00
—
...
0,00 0.00
0.00 0.00
_ —
N2 '
ati 1 M
—
...
—
,* ' 54 100
0,11' 2.16
0,11 1.86
_ —
H2S
: 0.00 0.03
...
0.00 0.03
0.00 0.03
CH30H
. 0.00 .0.00
—
~r
, 0.00- 0.00
0.00 0.00
'' ''r-y.
?:"2i93„ ,..,1O0.OO"
TOTAL
, 5,70 100.00
100,00
..;l.-',-54.'SS?100
4.90 100.01
5.70 100.00
Elements:
H
12 64 70.11
...
2 JO 8000
_ — „
943 "6727
12 64 7011
5 86 100 Ofi
C
2,79 1550
3.02 100.00
...
0,58 20,00
...
1,99 "14,20
2 79 * 15.50
, _
O
2.38 13 21
...
...
_
...
2.38, 17.00
2.38 . 13 21
N
0,21 1,17
—
...
l(3S.l4 100.00
- 0,21 131
0.21 1.17
8 -
S
0.00 ' 0.01
—
—
.tn.... - f->
_
0,00 0.01
0,00 ~ 0.01
* . —
Totnl elements
18 03 ioono
3.02 100.00
...
" 288 iQoi)
108.14 100.00
?4.oi 100,00
" 18.03' 100 00
^ , 5.86 100.00
Incns (kg/h)
3,17
._
Enthalpy:
JANAF
ash: h = -223 kcal/kg Hydrocarb
JANAF
JANAF
enthalpy =
JANAF
JANAF
60+67-10:
C: h = 2S7J kcal/kg
1+3+4+5+6+73-9
-105,914
kaolinile: h = 0
JANAF: -97140,9
-------
Hynol Actual HPR System
5/4/94
REVISION 7
62+63+64+65
90 + 91
7+2
some as 68
Sunup only
Stream #
63
64
65
66
67
68
68a
69
Properties
CO In
N2 In
Pre-HX Intel
C02 In
CH4 to cleanup
Preheater
Postlieater
Air
Q,kg/h
7.84
2J0
40,01
< 23.45
12.90
1 45rr" 7"
45,27
003
Normal m3/h
6.72
2.40
92.23* "
' 12.79
19.29
99.25, '
99.25,, -
' 0.02
Actual m3/h
0.23 .
* 0.08
3.13
" , 0.43
0.64
" 9-°?
' - 1140 -
00008' ¦
MW
28.01
28.00
10.41
44.00
16.05
10.95
10.95 v
28.84
Gnlhal. kcal/Ti
-7.403
0
-57,544
-50,140
-14422
-57.426
-43372
0
T.-C
25
25
25
25
25
525
10X1
25
P, »m
30
30
30
30
30
30
30
30
Components:
kmol/hi mole %
kmoVhr mole %
kmol/hr
rni)k%
kmol/hr mole %
kmot/hr mole %
kmot/hr mole %
kmoVhr mole %
kmol/hr
mole. %
H2
—
—
...
2,93,, /
76.24
...
2.93 70.85
253 70.85
' , ~
...
CH4
—
—
—
°-°°
0.00
...
...
'Sri oW?;
iopo
—
_ ' — ,
" _
CO
0.28 100.00
—
...
" 0,28,
7:29
...
...
...
0 28 S.77
0.28 6,7?
-
...
CO!
...
0.53
13.87
0.53
100.00
0 53 ,12.89
053 12.89
_
—
H20
0.00'
0.00
...
_
0,29 7.07
029 7.07
...
02
. 0,00
0.00
—
--
—
0.00
21.00
N2
—
0.10
100.00
o.to
2.60
—
—
~
* 040 •< 2,42,
. 0.10 2.42 :
' P-00;
79.00
H2S
...
o.oo-
0.00
—
-
—
' • •-
~ i
lr
—
CHJOH
—
',,'0.00
0.00
~
„.,:r
•**
—
TOTAL
0.23 100 00
0.10
100.00
3.84 10000
' 0.53 '
too.®
0 80 """
100;Q0
" 4,14 ,100.00
4,14 .10000
0.00
100.00
Elements:
H
—
—
5.86
71.30
*—
3,21
. 80.00
'6.44 " "70.85
< 644 -70.85
iSfttlSil
-
C
028 ' 5000
08!
5.89
0,53
33,33
0,80
'2000
0.81 'S.94
0,81 "8.94
; l. ,
...
O
0 28 50.00
—
...
' 1.35
16,38
1.07
66,67
—
1.64 ' 18.01
1.64. .• 18.01
itSSlSfS
—
N
^ -H-* 4C4H
0.20
100 00
' 0,20
2.4?
, —
0,20 • 220
0 20 2.20
0,00 ^
100.00
S
—
—
.-
—
—
—
—
* * *
A' *
' *
—
Total element!
056 >10000
020
100,00
8 22
100.00
1.60
100.00
4.02
100 00
' " t 9.10 1OO.O0
9.10 10WO
O00
100,00
Intro (kgflt)
--
Emhalpy: lANAF JANAF 62+63+64+66 JANAF JANAF 7+2 JANAF JANAF
JANAF: JANAF:
-57538.9 -59081.4
-------
Hynoi Actual HPR System
5/4/94
REVISION 7
6+67
12+70
post H-036
68A + 6
same as 81
same as 84
same as 74
Stream #
70
71
72
73
74
IS
76
80
Properties
Natural gas
Total CH4
Steam trap
"Recycle"
Water IIPR.SPR
Water stmjkts
Cltj water fe«4
Steam to SPR
Q, kg/h
18.07
27.31
-
5044
52.53
18.20
52.53
47.27
Normal m3/h
27.02 < ,
- 40,86
000 _
106.97
--
Actual m3/h
0.92 ~
0,48,
000*
>, 13,96
jwa , ""
0.02 <
MW
16.05
16.04
18.00
, 11.32 '
18.02
18,00
18.00
18.00
Enllial. kcal/Ti
-20500
-30,530
0
'50,996
-199367
-69,074
-199,367
•148^70
T, "C
75
23
233
872
25
25
25
235
P, mm
30
86
30
30
1
1
1
30
Comptmcrits:
krnol/ltr mole %
kmol/'ftr mole %
kmol/hr mole %
kmol/hx
mole %
kmol/hr mole %
kmol/hr mole %
kmol/hr mole %
kmol/hr mole 1i
H2 '
...
...
2 93
65,74
—
» — „
«-
,
CH4
1,13 100,00
1,70
100.00
_
0,32
7,22
* —'
< —" *—
""1, ' 1-1 '
CO
—
0 28
6 2S
,
—
< ****
—
CO!
-
«L.
053
11.96
—
mo
...
0 29
6 56
2.92 100.00
' 1.01 100.00
2.92" 10000
2 63 100 00
02
...
--
...
—
— ^
_
< <•
— ' ^
N2 !
_ .
—
010
2,24 A
~ v...
— ,
H2S
—
~
—
:
' *—v **-__&¦ ~
'' —
CH30H
—
...
—
—
>'• *• ~ ,
liSSfIlliSlSSIsS
TOTAL
1,13 ; 100.00
1.70
100,00
0 00
, 4,46
100 00,
2.92 10000
1(11 100 0C
191^ 100.00
\ 2.63. 100 00
Semen Is:
H
, 4,50 so.oo
6 81 '
80 00
_
7.73
72.23
5.83 66,67
"< '2 02 '-'66.67
'' S,'C " 66.67
< 5,25 66 67
C
" 1,1 J to 00
¦.-"'IrlO '
1,14
10.60
. r.'
tfe.
0
...
—
1.64 „
15.30
- ' 2.92 33.33
1.01 < 33.33
2.92 ' J 13.33
2 63' 33.33
N
0:0
1.87
—
S
—
A-
...
..
•-
aL
s— '
Total elements
5 63 100 CO
8 Si
100,00
000
10.71
100.00
8,15 iWOO
"5,03 „100.00
, 8.76 ' lOCCOO
7,88 100.00
Inerts (kg/h)
Enthalpy:
JANAF
12+70
JANAF
JANAF
JANAF
IANAF
JANAF
IANAF
-------
Hynol Actual HPR System
5/4J94
REVISION 7
2+80
82+83
some us 82
same as 83
Stream tt
81
82
83
84
85
86
90
91
Properties
Steam HFR+SP8
HPR steam Jkt
SPR steam Jkt
Steam Jackets
IIPR condensate
SPR condensate
C1I4 to HPR out
CH4 purges
Q.kgAi
52.53
9.10
9.10
18.20
940
9 10
10.97
, 1,94
Normal m3/h
70.04
12.13
nn
24,27
— x '
J 6 41 <*
™.2.90
Actual m3/h
4.06
1.18
148
2.36
^ j
,001
001 ^
.056.._
035
MW
18-00
18.00
18.00
18.00
18.00
18,00
16.04
16.04
Ensh»l. kcal/h
-165,102
¦28,692
-28.692
-57,385
-12259
-1356
T, °C
235
204
204
204
25
800
P, atm
30
16.8
16.8
16 8
30
30
Components;
kmol/hi . mole%
kmoVhr mole %
krnol/hr
nole %
fcnoWir mole %
kmol/hr mole %
kir.o'./hr mo!e %
kjnol/hr mole %
kmol/hr mole 7s
H2
—
...
—
-
—
...
—
--
—
_
CH4
—
—
—
—
...
-
...
...
0 684 100 000
0.121 100 000
CO
...
...
• -
...
-
...
...
...
...
-
—
C02
—
—
—
...
—
—
—
—
...
--
--
...
H20
2.92
100.00
0 51
100.00
031
too oo
lOl
10000
0.506 100.000
0 50^ 100000
—
—
02
—
—
--
...
—
~
...
...
...
—
—
N2
—
—
...
...
—
--
—
—
H2S
...
—
—,
— "
...
... ¦
—
—
—
...
CH30H
...
•-
r* > >
...V
T.
—
— ^ ^
»> V
...
TOTAL
2.92
100.00
0,51
100.00
0,51
100.00
-
loboo
o Si moo
0 506 100 000
0.63 ' 100 00
' 012
100,00
Elcmentf:
*
'
•,y", Mv
H
5.84* '
66.67
101
(A 6"
1.01
<16.67
' 2 02 >
66.67
,'j.Ot 66.67
- }.oi "-i&h
-2.73 '8000
0.48
80.10
C
.m•
—
...
...
,
""
0,«« 20 00
- 0,12
20.1X1
0
2.92
33.33
0.51
33.33
0,51
3333
1,011
33.33
0.51 ' 33.33
051 ' 33.33
.J • ^ <_
' , ~*
N
—
—
«*»
—
' * *'**
'*v
¦i
—
S
~
— *
*-
\ —
*-
--
Total elements
8,76
100.00
I St
100.00
1.52
l'-O <*)
, 3,03
100 00
1:52" 100-00
1.52 100.00
•' 3.42-' ,.100.00
0.6Q
100.00
lncrts (kg/h)
Enthalpy:
JANAF
JANAF
JANAF
JANAF
O-
IANAF
IANAF
-------
mm
90 + 92, or
REVISION 7
60 + 91
60 + 67
Stream #
92
93
Properties
HPR out ~ purges
To F-104
Q,kg/h
7649
, - - 87.45
Normal m3/h
120.51 „ *
• '136.90 ,
Actual m3/h
¦ 14.14 - ^
j : is.49.
MW
^ 15.23 -•
" 15.33" -
Enthal. kc*!/h
-98.438
-110.801
T,"C
800
720
P, aim
30
30
Components:
kmol/hr mole %
kmol/hr mole %
m
1.835 35537
1.835 32 J«l
CH4
1.075 21.413
1.758 30 S24
CO
0.658 13.096
0,658 11.528
C02
0.378 7.534
0.378 6 632
H20
0.968 19.283
0.96? ]6 974
02
—
N2
0.106 2.108
0.106 ' 1,855
H2S
0.001 0.029
0 001 '0 026
CHJ01I
—
TOTAL
5.02 100.00
" 5.70 100.00
Elements.
H
* 9.91 *, 57.80
12.64 ~ 70 Jl
C
2,11
' 179 15,50
0
231 16JO
' 2.38 15.2!
N
0?1 1,4$
031 1.17
S
0 00 0,01
0 00 0.01
Tom! elements
14 62 100 00
18 03 100.00
Ineits (kg/h)
Enthalpy: IANAF JANAF
60467;
¦105,914
Hynol Actual HPR System
-------
eONBENSAte
o
T-513
LH-601
a
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¦m-
-v*5
F-521
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OAS
NOTE:
Acurex Environmental Corporation
HYNOL
PflOOF COPY FLOWSHEET D
an
CORRECTED ROW DATA
DJT
HPR
PROCESS FLOW DIAGRAM
RELEASED FOR REVIEW
RELEASED FOR REVIEW
0/F
8570G002
HEFEBENCE DRAWINGS
-------
r=r~««-
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Mi (UMmtmi
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tUHLW
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I (l>il mm)
(tun a* Mb
mjsh^
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PROCESS
STEAM
BASX4E I HAHlitt
•EES^i
PROOF CQlt FLOWSHEET 0
NOTE:
I fTAUCS t
Mtem to ricvtxtrr tr catto »««
O.J. TATE 044M4
Aeurex Environmental Corporation
HYNOL
CORRECTED FLOW DATA
RELEASED FOR REVIEW
RELEASED FOfl REVIEW
HPR
PROCESS FLOW DIAGRAM
CWIMHWg QMCI
REVISIONS
REFERENCE DRAWINGS
B
8570G002
2 ol 2
rev
4
-------
_L
>
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Acurex Environmental Corporation
HYNOL
CORRECTED PER NEW FLOW DATA
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REFERENCE DRAWINGS
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PIPELINE DESIGNATION NUMBER UST
AND OPERATING / OESlGN CONDITIONS
JWOIECT M4i«; MYMOL Hpf POI - Type 316 Signless Sreal TufaAj with Swagniak Frying*
Pkuect nukma- 6ITO-IO0 Pft2 ¦ 00 Blacfc Pipe w P •< PvAmi
FLOW
»AC*U}
(*CfU»
iscrwi
I - »I"W - 1/2 • P03 * 01 •
i570G003 sh 4
Ooilec Feed W« l«
o?3 asm
>15.6 IbsJhi
OSgpm
0 69
Siatft Head
Amttart
1 - Df-w - u* - PDi - 02 -
I370G003 sh 4
Bolter feed Water
0.23 dom
115.6 fba/ht
0.5 asm
B 84
M5J
Arti&ent
2 - m-'W - 1/2 * P03 '» 01
8S70G003 »h 4
Ek*fef Peed w«f»r
OOSdpm
40 Bwi/hr
OJSoom
. 0 C.5
SiaHc Head
Ambiert
2 • niw . 1/4 - POi 02 ••
83700003 ih 4
BoQer Peed Walsr
O.Mopm
40l6i/fw
0,5 com
8 64
232 3
Air^em
c • 3/i • poi oi •- i« in
*5700003 sh 2
Corxjenss?*
0 04 gprn
200lb4Ar
0J Gpm
iM
232.3
C ¦ 3/8 . POI - 02 t* 1 n
8570G003 it! 2
Condensate
0.04 (jpm
20QlbsAtf
OSoom
2 66
Siane m«d
V^lKiTK)&&&<
- c ¦ j/s • poi - 03 - i» \ n
On SPR Facihiy
Condensate
OD4 opto
SdOlbs^f
0.5 qom
2.E8
232-3
XVTZTBDmZ
C ¦ 3/8 - PO1 - 04 -• U 1/5
I57QGO03 th I
€on POI - OS ¦ U 1(7
I310C003 ih 1
Condensa!*
009 qpm
OSqpm
2C5
Slalk H**d
CA - %n - P03 • Oi -
I570G003 ih I
Air-
2005/ 1.00 N
205/1 ON
soo
Si 25
0
AmKew
• CA • 3/8 - P03 ~ 03 -
S570G003 ih 1
M
005 3/0-02 N
20S/I.0N
SCO
2.04
600
Ambianl
- Ca • 1/4 - POI - 03 -
8370GOO3 sh i
Att
G0SS/O02N
2.0SM ON
500
15.61
600
Amfcnertl
. CA - 1/4 • pnt - 0 4 -
•I570GOO1 ih i
Air
0 0? S
1 OQS
ZOO
833
600
Anttem
¦ ' Ca - 1/4 • POI ¦ OS •
3510G003 «h 1 4 3
Ait
003 S
100S
200
0 tQ
465 3
Ambf
0 0033 S
0 >0 s
?oe
S8«
<2S3
Amhdfil
Ca - I M POI - OJ -
BJ70G003 »h 3
Ai»
0 93 S
200
8 ft4
*25.3
Ambisrl
CA - 1 M - PO 1 * OS -
R37CGOG3 >h 1
Ail
0024 N
X OO N
200
6 33
600
Ambism
/
. <-{) . ! /« POI - Oj .
R5m.fK)1 *h 1
Cflfbnn MfiAoxtd» Gm ~ 1/4 . POI . 06 -
1570G 003 >b 4
CO. CO?, H2, m
00 la 084
0 0 lo 15 0
2500
11047
425.3
Amcxoffi
1 • MCj • 1/2 - POI - 07
8370C003 th 4
CO. C02. H2. N?
337 S/ 1.81 N
toea« S/S4.29N
125.00
93 27
4253
Ametenl
1 . MC - 1 1/? - PO* ¦ 08 -f
Z570GG03 ih *
CO, CCS, H2. N2
10D&aS/£4.J,6N
100S65/M2SN
125.00
165 77
0
Ambwnl
I - Ms, . i m - P04 . 09 -
JIJ70C001 ih «
CO. COi'. M7. H2
l00ftSS/S4 29M
I0OC8 S/ S4.29 N
125 00
169.7?
0
Amfwni
j - Mr. - " 1/2 - P04 - io - l*i
8S70G00J %b *
» 3M* CO. 7 22% CO?, 39 66% H2.
*5.32 % K2
Nomtg . 7.31 %CO, 1369% C02, 76 24% H2.
2,57 % H2
10.04 S/MO N
10© 86 siunn
IMOO
127-50
4253
1tiJ
i . Mti - 1/2 - POJ . II • l-l
8570G00J »h 4
Siart-to • 3.66% CO. *94% C02. 36.13% H2.
3.65 % H20, 47.42 % N2
NOfBWI ¦079% CO, 12B9% COZ. 70-73% H2.
7,t5 % HZO. 2.38% N2
9S0S/6.20N
104-40 S/ 67.fi H
I2S00
116 55
425,3
977
1 ¦ MG . 1/2 • P04 - 12 - l-l
I3TOGOOI ih 3 4 4
• 3.66% CO. 6$4% CG2. 36 O % H2,
3.85% WO. 47.42 % N2
Normal • 6.79% CO. 12.89 % C02, 70.79% H2.
7.11% M?0, 2 38% N2
15.15 S/t.391 N
IO«.40 9/57.11 H
«500
18591
<25.3
1832
-------
\
PIPELINE DESIGNATION NUMBCK tfST
AND OPEfiATTNG/DESIGN CONDITIONS
PHQCfcCT «AMC
PROJECT MUfcrfJC*:
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H« MUUOFR
HtWOL Hpt
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April as. 1W4 *r 11:39 AM
POI m Typa 316 Siainless "ileal Tuturvj w*!fi Flu^gs
P02 m. Sch BO Black Psp« wi|h 3000-Pound Forced Sleet 5ere»w0 fil9r»gi
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Page 2
l.INK DESIGNATION NUMRER
P&iD Nft.
FLUID COMPOSITION
i*U ffcRCt^TAaEb *«i MlXt
DENSITY
l«*ms>
OPERATING FLOW
DESIGN
flow
ISCFU} .
DESIGN
VELOCnV
t A/P9 J
OPERATING
PRESS.
If*!
DESIGN
PRESS.
Sysism
0 01 N
0 62 N
2.00
598
635.3 ¦
An^am
7 t- NJ l- 3/4 '-f POJ 04
f570G003 Jh 1
System
0 02 N
062N
2.00
oru
425.3
Ambieni
7 1- N2 P 1/4 1-5 POi •- 0 3
I570G003 th I
NiiroooGas (N2J System
0023N
1 EON
200
5 99
6353
Arribiani
2 h- N3 f4 |/« TGI 06 i.:
*5100003 tb 1
NiKoQen Gm (W! J Syslem
0.035 N
1 00 N
2.00
as*
425.3
An^am
2 js.1 N2 |/2 M POI f4 07 M
IS70G003 A 1
Nitrooen Gbi 1 N2 ) Svilem
0.033 NJ7.02 P
1,0 N/.2IO.O P
250.00
186.43
425.3
An^am
2 F~; NJ M 3/2 t-l FQI <"-¦ 08 J*
t570G003 *h 1
NiHofjunGis J Sysltm
103 P
2100P
250 CO
Mfi.43
425 3
AfrtMsril '
1 K' HI M |/« fj POI 09 F-'
H570G003 ch 1 M 3
Wil'wjert Ga* T N2 | Sr*i«fn
0 23 P
%OOP
1500
44 87
635 3
Amklanl
2 fci N2 1/4 M POI JO r-\
8570G003 lh 2
Nlwooefl Gbj f N2 ) Svlltm
0.2SP
10.0P
15 00
48 Si
6853
AmlManl
2 fci N? fa 1 /J M POI U* 1 1 !-«
B37GGOQJ lh 7
«iiioo*ri Go* ( N2 > Sfitem
0.33 P
IDOP
1500
85 29
4253
Anrtriera
2 P N2 14 1/4 J-l POi M 12 N»
6370G003 ih 2
Wiifooen Gas i N2 \ Stsicm
033 P
10OP
15 00
68 2S
<28 3
Ajnljianl
3 M m r4 !/« M POI >¦+ 01 Cl
13700003 th 1 ft 3
Nitfoq*rtO*l ( N? ] H«jh Pfcjsurn
oooi saw
Q ia N
200
1.85
2085.3
3000
AmWanl
•¦3 W-i N2 |-1 J/4 M POI '-i 02 f^-1
R57OG0O3 *h 3
Nil>OQ«r)G*l IN?] H'Qh Pr»;fuf«
O.OODfi N
0 OB N
2.00
1.85
2985 3
3000
AnvMam
3 M N2 r-i J/4 M POI OJ "»
B370C003 ih 3
MroQerv Gti jN2 1 Hi*t\ P(e«u>e
00006 N
ooan
2.00
1.94
1085.3
3000
AiyAiarH
3 F.I N7 s4 1/1 V-l P04 ;•-> 04 rJ {.i
e3?QG003 lh 3
N>lf«}er>GM (N2J H«ih ffejiu't
23 97 N
707 OP
850 00
272.2©
885.3
3000
£50
3 W N2 IT |/4 POJ OS M
8510GOO3 lh 3
NiiroqcnGil < N? 1 Ngh Prisaur«
0 000? N
0 ION
2.00
1.85
2085,3
XCQ
Ai^Nam
3 i-i ft 2 N 1/4 POI t~- 06 fc}
IS70GQ01 ib 3
NnrDctencn 1 «2 ) Hkyt Preiaura
oon.ii n
0 ION
200
8.10
485.3
600
Amblirfl
3 I1-' N2 k<) |/t M POI OT N
I37OC0O3 ill 3
Ntfroqtn Gas (N2 | High Prastut*
00017 N
005N
1.00
33 75
425.3
600
Am&fartt
J f-' Nl U 1/4 5*3 POI *-* 01
8370CD03 ih 3
NlrrooenGai f N?) H»ghP#«iSu«
0,0017 N
0.05 N
100
33.75
•25.3
600
Amtxenl
4 r- N? Nl 3/1 POI •• 0 1 -•
&570G003 ih 1 ft }
Ges {N2J Eme«j«f*ry
2 97N
09KJ N
1 TO. 00
T4S.36
425.3
Aittoam
i- KG J:^ i 1/2't* P02 OIK
15700003 ih 1
Naluraf Qat (CH4>
1S.02S /
14.37 N/
20 32*
, 25.24 S/
Z4.I4N/
34. MP
45 00
3837
10
Afl^iem
NO j-j \ POI - 07 .
IS70G003 111 1
Natural Gas (CH4 \
029S/
02a Nf
O40 P
25,24 S /
24.14 Nl
34.14 P
45 00
1.75
1250
Anjfc"en|
- no j-; in PO! - 03 r-
8S70G003 ih i
NaHxal Gbi 1 CH4 {
0.29 S/
0 28 HI
0«0P
25 24 51
24.14 N t
34 t4 P
4500
it m
1750
Ambient
Nr. j- J/B - POI ¦ 04 .
857OG00J rt 1
NaiufalGai (CH4)
0.20 S/
DliNf
0»P
17.10 S /
IB 00 N /
?6 00P
3500
16.20
1250
Amttanl
NG 5/1 POI - 03 i-;
8570G003 th 1 A 2
Kalurar Ga« (CH4 }
0.23 S/
0.2! Hf
0 34 P
U.IOS/
16.00 N1
29.00 P
3500
1B3fl
1100
Afl^cni
NG 1/4 POJ - Ofi
«570G003 »h 2
N&!y^Gb» 1CH4 )
00013 N / 0 .13 P
0 t N/10 1 P
15.09
26.38
1100
Am&ia^t
No 1/4 -¦ POi >- 07
8570G003 ih 2
Natural Gas (CH4 1
OD02SNfO,2SP
0 1 N/10. t P
13.00
40 61
585 3
Ambienr
NG \tt ¦ POI • 01
S570G003 ih 2
Natural Gas f CH4 )
025P
10.0 P
1500
48.61
5853
Ambtoi!
T- no I-' i/a POi '• of
8510G003 *h 2
NaiuraiGas (CH4)
00017 N
0.05 N
2.00
67.50
4253
Ambherri
m i' i/4 ?;{ poj u- io
8570G003 »h 2
N»IixaIG«s (CH* )
0.31 P
10.0 P
15.00
88.28
4253
Anient
NO t<4 l/< POI -!'*• II
I570G003 iK 2
Natural Gas t CH4 )
0.0017 N f .034 P
0.05MM003 P
15.00
«4.2S
425.3
A/nbienK
r; mg {-* hi poi r.- 11 i-*
8570G003 ih 2
N»lural Gas ( CH4 J
00017 N
0.05 N
200
&7.S0
42S3
Am Went
?- Nr, |iv i /4 •-"! POI 13 •-«
8570G003 »h 2
Natural Gas fCHil
033 P
10.0 f
15-00
68 28
425 3
Amblftft!
I. NG }'* I/4 POI I-' 14 K/
8570G003 »h 2
Na'u/al Ga« t GH4 J
ODOI7N/ 034 P
0 .05 N/10.05 P
1500
&8 28
425 3
Amfaicnl
<•' NG i'.'i W« T4 POI I'- 15 k
837DG003 ih 2
Natural Gas t CH4 )
0 22 S f 0,21 N
17.00 S/15.8 N
13-00
43.60
I1CO
Ambienl
%' NO I.*4 l/< *=l POI u M
«570G005 tb 2
NaluraJ Gaj [ CH4)
0 I5N
11.35 N
1500
26,16
1100
Ambierrt
NG M }/< W POI b 17
1570G003 *h 2
Natural Gas [ CH4 )
O.iaN
9 95N
1500
26t8
1100 I
Amfii«rM
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-------
t— .
. PlPfl iNE DESIGNATION NUMflCR I.JET
AND OP€«AT!nG/DESIGN CONDITIONS
Huxikd N*.Mt NYNOl Hpr PCM ¦ Typ«3l6 Si&nlasa &l#el Tuning MihSwsgHCBi
pmxitcf HUMKH- as^J.300 ' <*02 - SchMBI«d^PSpe*flff»3OO0-PounrfF»ge^Sl«®f . PagB 3
wvacw 0*Tf Aprb 25. 1994 al !1:39 AM , P03 ¦ Sch 80 Gatanfred Plpft Wlin 3000-Pe*«? FntgtHS S'ert Screwed Fin^gs
fit numhfs GC03-1—MPR Lin# Dcilqr\*ilon U PW - 5th 80Tip* Jig SaMMt Siert Pl»»«h 3000-Po^ Forged Stetf WffldFBib*»«
l.rNF. MEStCNATlON NtlMIIRK
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FLUIU COMI'OSJ riON
CAil 'I^CNTACES ABE MC\S *(
DKN.Ml Y
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OPKKATlN(; H.OVV
DfcSlGN
OKSIGN
VELOCITY
IVPSI
OFKBATING
PRESS,
IW!
DKMGN
PRESS.
19M»I
UJ'KMATIWC
TEMP.
i*i
or.sicN
TEMP.
l-'i
S?ST.; stnwce .. Wl j I . UNI .« MSVU •
Afl€» *fla« 1. $ut 'J* M&t - ' Me. it ft«cie.
ANI>
SHEET No.
S • Stifli®, N - wm'W MP* F>i*m
FLOW
(AOTM)
(GCFM)
- NO 1/4 *¦' POt 18
I570C003 ih 2
Natural GfiJ ( CH4 1
0.30 N
935N
1500
GO 78
465.3
AmEaenl
NG J/8 f-i POJ l- If :J
I570G003 ih 2
Na1ur«lGi« ICH4?
0-0017 N
0.05 N
2.00
87.50
4253
Amtwrni -
. fiC} - Iff M POt ao '
HJ70H003 «h 2
NaluralGsj fCH4)
OUON
990N
1500
60 76
465 3
Afl»6«eW
. Nd i/b *i' roi >.• 3 i .•
«j?w:on3 ih i
G*s ICH'l
0 0017 N
005 N
2.00
67-50
425.3
• N(i - 1/4 ,-1 POI % 22 it
8570C003 ift 2
N«rursl€8S (CH4)
oaoN
985N
1SIXJ
50.78
4653
AmWenf
NG U Ui POI ?;• ?J
I570GD03 »h 3
NafuralQas (CH4 }
0 .0017 N
005N
2.00
67.SO
425.3
A?rifc4enS
NG *~ 1/4 jM PQ1 t- 24
8S70GQ0J sh 2
NslursIGai (CH4)
0.30 N
9 80N
15.00
6078
465.3
Ambient
. NG 1/8 M POJ 23 i-'
I570G001 »h 2
Natural Gas fCM4l
00017 N
0.05 N
2.00
57 50
426 3
Amdem
- mi '» | /4 U POI U' 26
8V10Gm>« ih 2
N*iutftlG8a fCW |
0 30 N
9 75 N
1500
60.70
465 3
NO | /H *.! p0| J? .
K^IOCnO) »h 1
Naiutal Gbs ICH4 1
-
00017 N
0 05 N
2.00
67.50
4213
Ambwrt
- iw; 1/4 C-I POJ J* ¦'
B170G003 sh 2
Naiural Gas f CM4 }
0 30 N
9 TON
15.00
007S
405.3
AmfaenJ
~ NO 1/f M POI 29
IS7OG00J «h 2
Natural Gas f CH4 1
0.0017 N
0 .05 N
2.00
67.50
425.3
AfflbHNU
NO ).< |M fcl POJ f-' 30 **.
S570G003 »h 2
Neural G» (CH4 j
0 32N
9 65N
15.00
68 28
425.3
hm '
NG f-» 1/4 *-! POl M! 3 1
83700003 th 2
Ns.'utat Cbs (CW4 ^
0 02 N
I 40 N
200
3 49
1100
AmbteW
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nwnaxn %n i
NaiuralGaa (CIU 1
OOJUtOOSL
1 *ON
?m
rt m
99^ 311/ 3 i
AinbirnJ
mi t/4 fin j. ii .
M^7(K»l()1 2 A 1
HJiuiiit Gns (ClU)
OD?S/OfK"iN
5GSSM55N
»0,00
1744
1100
Arnbimf
. N(i - 1/4 - pyi •. M .
K57(Rr(«)J ib 3
Nf jaJ Gaa t CH* 1
O.IIS/OHN
5,65 S/4.55N
to 00
«0 51
465.3
Ambient
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8S70G0G3 ih 3
Ntiurai Can f CH4 |
0.003 N
0 ION
2.00
B m
4253
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•* NG 1/4 T.» POI »•-* 36 i-i
8S70C003 ih 3
Naiuraf Ou (CHH)
017S/0.14N
$,55SM,5SN
10,00
4051
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R 5700)03 ih 3
rwi-jral Gas i 0H41
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10 5
200
864
425 3
Amtneni
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H^7flf3il03 %h .1
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0 15 N
liSN
1000
it |9
425.1
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*^T«K,{Kn vh I
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OWH
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Product bulletin
CELANESE
CHEMICAL
COMPWNYJNC.
CELANESE CHEMICAL COMPANY. INC 1250 WEST MOCKINGBIRD LANE DALLAS, TX 7S24? PHONE: 214-689-4000
METHYL ALCOHOL
(Methanol)
(Carbinol) ch,oh mw=32.04
(Methyl Hydroxide)
(Monohydroxy methane)
Methyl alcohol is a clear, colorless, mobile, highly polar liquid with a mild odor. It is miscible with water,
alcohol and ether.
Although the largest end uses for methyl alcohol are in formaldehyde production, dimethyl terephthalate and
chemical intermediates, its uses as a solvent, extractant and fuel additive are also of considerable importance.
Methyl alcohol "is used extensively as an intermediate in the preparation of methyl acrylate and methyl methac-
rylate, methyl chlorides, methyl ethers, dimethyl sulfate and many other intermediates and dyes. It is used to
solubilize phenolic laminating resins, ethyl cellulose, cellulose nitrate, gums, shellac, vegetable wax, and
many other resins and oils. Miscibility with most organic solvents further enhances its solvent properties.
Solutions of gums and resins in methyl alcohol usually have a lower viscosity than is possible with other alco-
hols. This alcohol is an excellent fuel for high-compression.reciprocating engines as well as a component in
Jet and rocket fuels. It is used as an anti-freeze agent in gasoline, Clean burning and easy to handle, it is used
to fuel heaters in insulated railroad freight cars carrying perishables.
Methyl alcohol is one of the basic raw materials of the organic chemical industry. The Celanese product is
available with a purity of not less than 99,85 per cent. Celanese methyl alcohol meets Federal Specification
0-M-232F (September 27, 1974} Grade A.
Methyl alcohol undergoes reactions typical of aliphatic alcohols.
CHEMICAL REACTIONS
1. Reaction With Hydrogen Halides
CHsOH + HX——- CHjX + HiO
2. Reaction Win Active Metals- Reaction As Acids
2CHiOH SU „ jCHiONa + H.
3. Oxidation
CHiOH m ^HCOOH + HiO
4. Ester Format.on
,£H,OH + CHjCQOH CHiCOQCHj + H.O
5. Reaction With Carbon Monoxide
CHiOH + CO » CHjCQOH
Methyl Alcohol, Chemical Abstracts Registry Number 87-56-1; Wiswesser Line-Formula Chemical Notation Q1
1
A-22
-------
SPECIFICATIONS
METHYL ALCOHOL, REGULAR GRADE
METHYL ALCOHOL, PREMIUM GRADE
Methyl Alcohol Content, wi. % min.
Color, Pt-Co Units, max.
Acidity, as Acetic, wt. %, max.
Permanganate Time, Minutes, min.
Acetone Content, wt. %, max.
Odor
Appearance
Wafer, wt. %, max.
99.85
5
0.003
50
0.003
Characteristic
Free of Foreign Odors
Clear and Free of
Suspended Matter
0.10
Methyl Atcohol Content, wt.%, rnln.
Color, Pt-Co Units, max.
Acidity, as Acetic, wt. %, max.
Permanganate Time, Minutes, min.
Acetone Content, wt. %, max.
Ethyl Alcohol Content, wt. %, max.
Odor
Appearance
Water, wt. %, max.
99.85 -
5
0.003
50
0.003
0.010
Characteristic
Free of Foreign Odors
Clear and Free of
Suspended Matter
0.10
PHYSICAL PROPERTIES
Autolgnitlon Temperature, "0 470.
Boiling Point at 760 mm Hg, * C. 64.65
Boiling Point at 760 mm Hg, "F. 148.4
Coefficient of Cubical Expansion per °C
at 55" C. 1.24 xlO"3
Critical Pressure, atmospheres 78.7
Critical Temperature, *C. 240.0
Dielectric Constant, mhos, 25 *C. 32.63
Electrical Conductivity at 25*C., mhos/cc, 1.5 x 10 "®
Evaporation Rate (BuAc = 1). 2.0
Flammable Limits {lower limit, vol. %). 6.701
(upper limit, vol. %). 36.0
Flash Point, Tag Open Cop, *F. 60
Tag Closed Cup, *F, 54
Freezing Point, *C. - 97.8
Heat of Combustion, caligm,, gas, 25 *G. 5683
Heal of Combustion, caligm., liquid, 25*C. 5420
Heat of Fusion, caligm, 0.76
Heat of Vaporization, caligm. (at normal
boiling point). 262.8
Molecular Weight (formula). 32.04
Reid Vapor Pressure, pounds per
square inch. 2.2
Refractive Index, nj1 1.3285
Solubility at 20 *C, wt. %, in water. Complete
wt. %, water in Complete
Solubility In atcohol, ether or water. Complete
Specific Gravity, 20/20'C. 0 7923
Specific Heat of Liquid, cal /gm./'C
at20"C. 0.599
Specific Heat, cal./gm./*C at 0°C. 0.566
Surface Tension In Air at 20 *C., dynes/cm. 22.55
Vapor Density (air = 1). 1.11
Vapor Pressure, mm Hg, 20'C. 96.0
Viscosity at 20*C. centipoises. 0 614
Weight, pounds per gallon at 20*C(68"F). 6.59
PRECAUTIONARY INFORMATION
Health Information
Methyl alcohol Is highly toxic by oral ingestion; as little as one to four ounces can be fatal or result in
permanent injury such as blindness. A physician must be called immediately to treat anyone who has ingested
methanol. The vapor at high concentration causes irritation of the eyes and respiratory tract; inhalation of
excessive amounts must be avoided. Repeated or prolonged contact with the liquid or vapor causes skin
irritation.
The exposure limit for methyl alcohol is 200 ppm (260 mg/m3) based on an 8-hour time weighted
average.® Where exposure may exceed this limit approved respiratory protection should be readily available
(or use in accordance with government regulations. Workers handling methyl alcohol should wear chemical
safety goggles and impervious gloves. In case of eye contact with methyl alcohol, flush immediately with
plenty of water for at least 15 minutes and seek medical attention. For skin contact, flush with water. Remove
contaminated clothing and wash before reuse. Discard damaged protective clothing and contaminated leather
shoes, if swallowed, Induce vomiting immediately by giving 2 glasses of warm water and inserting finger down
individual's throat. Never give anything by mouth to an unconscious person.
For further information, refer to the Manufacturing Chemists Association's Chemical Safety Data Sheet SD-22.131
(1) "Fire Protection Guide on Hazardous Materials", National Fire Prelection Association, Sixth Edition, 1975.
(2j , 29Coda Federal Regulations 1910.1000
A-23
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Safe Handling Procedures
Methyl alcohol is a flammable liquid; it exhibits a potential fire hazard wherever it is stored, handled or used. It
should be kept away from heat, sparks, and open flame. The vapors are toxic and heavier than air. Adequate
ventilation of work and storage areas is essential. The concentration of the vapor should be kept outside the
flammable limits.
Building and equipment design for handling methyl alcohol should conform to all applicable National Fire Pro- .
taction Association standards. Electrical equipment should conform to Section 500 of the National Electrical
Code."' No apparatus capable of providing an ignition source should be used. Because sparks from static
electricity can ignite methyl alcohol vapor and air mixtures, it is imperative that safe handling procedures,
such as adequate grounding and bonding, be developed and strictly observed.
The practices recommended in the M.C.A.01 Manuals, TC-29, "Loading And Unloading Flammable Liquid
Chemicals-Tank Cars," TC-8, "Recommended Practices For Bulk Loading And Unloading Flammable Liquid
Chemicals To And From Tank Trucks," and Safety Guide SG-3 "Flammable Liquids: Storage And Handling
Drum Lots And Smaller Quantities" and the M.C.A. Chemical Safety Data Sheet SD-22 should be used as
guidelines for handling methyl alcohol.
Small containers should be protected from physical damage and stored in a cool, wel-ventilated flammable
liquids storage area. Bulk storage tanks should be located outside and detached from other buildings. All
sources of flame, sparks, ignition or excessive heat should be removed from storage areas. Storage ol methyl
alcohol should be in accordance with the provisions of the National Fire Protection Association w Pamphlet
No. 30, "Flammable And Combustible Liquids Code."
Carbon steel (lined or unlined), 304SS, brass or copper are acceptable materials for construction for use with
methyl alcohol. Aluminum is not acceptable from a color and contamination standpoint.
In the event of a spill, remove all sources of ignition. Keep personnel away from spill area. Dilute spilled
material with large volumes of water. If spill is contained in a relatively safe location, cover with an approved
foam as a precautionary measure for fire and fume protection. Dike large spills and dump into salvage tanks.
Prevent washings from entering all waterways. Disposal should be carried out in compliance with federal,
state, and local regulations regarding health, air, and water pollution. Notify authorities in the event of major
spills. Incinerate waste in chemical incinerator.
PRODUCT SHIPPING INFORMATION
D.O.T. CLASS Flammable Liquid
FLASH POINT *F TAG OPEN CUP 60
CELANESE LABEL NUMBER
DRUM
SAMPLE
TANK CAR-TANK TRUCK
FREIGHT CLASSIFICATION
I, BULK SHIPMENTS
Tank truck {Full) 40,000 Pounds Minimum
Tank car (Full) 10,000 to 30,000 Gallons
II. Filling Points
San Pedro, California
Chicago, Illinois
Newark, New Jersey
Cincinnati, Ohio
New Kensington, Pennsylvania
Rock Hill, South Carolina
Bay City, Texas
Bayporl, Texas
Bishop, Texas
Clear Lake, Texas
Pampa, Texas
II. DRUM SHIPMENTS
Are not presently available,
(3) Manufacturing Chemists Association, Inc. 1825 Connecticut Avenue, N.W. Washington, D.C. 20009
(4) National' Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210
A-24
D.O.T. LABEL Red{3)
TAG CLOSED CUP 54
OCD-47
OCD-47-1
OCD-47-2
Methanol
-------
HEADQUARTERS
DALLAS, TX.
CELANESE CHEMiCAL COMPANY, INC.
1250 Was! Mockingbird Lane
Oatlas. TX. 75247
Phone: 214-68M000
ITT Telex: 914-861-4049
DISTRICT OFFICES
BOSTON, MA.
55 William Street
Weilesley, MA. 02181
Phone; 617-235-1790
CHARLOTTE, NC.
P.O. Box 32414
Charlotte, NC. 28232
Phone: 704-554-2511
CHATHAM, NJ.
26 Main Street
Chatham. NJ. 07928
Phone: 201-635-2200
CHICAGO, IL.
4825 N. Scott Street
' Schiller Park, IL- 60176
Phone: 312-678-6330
CLEVELAND. OH.
24700 Center Ridge Road
Westlake.OH, 44145
Phone: 216-835-4333
DETROIT, Ml.
26711 Northwestern Highway
Suite 530, W.8. Doner Building
Southfield, Ml. 48076
Phone: 313-353-9680
HOUSTON. TX.
5 Greenway Piaza E.
Suite 1710
Houston, TX. 77046
Phone: 713-621-B400
LOS ANGELES, CA.
21515 Hawthorne Blvd.
Union Bank Bldg. Suite 801
Torrance, CA. 90503
Phone: 213-772-3488
ST. LOUIS. MO.
734 West Port Ptaza
Suite 271
Si. Louis. MO. 63141
Phone:314-434-9S9S
WILMINGTON, DE.
Suite 102
Hidgely Building
Concord Plaza
3519Silverside Road
Wilmington, DE. 19810
Phone: 302.478-9005
INTERNATIONAL OFFICES
ASIA, AUSTRALASIA
THE far EAST AND THE AMERICAS
AMCELCO., INC,
1250 West Mockingbird Lane
Dallas, Texas 75247
Phone; 214-689-4000
ITT Tele*: 910-8B1-4049
Cable: CELANESE Dallas, Texas
EUROPE. AFRICA, MEDITERRANEAN
AMCEL EUROPE S.A.
Avenue Louise, 251
B-1050 Brussels, Belgium
Phone: 6498020
Telex: 22126
Cable: Amcel Brussels
To the best at our knowledge, the mtarmatian contained herein is accurate. However, neither Cetanese Corporation nor any 01
its attitiates assumes any liability whatsoever tor the accuracy or completeness ot the information contained herein. Final
determination of the Suitability o f any intormation or material tor the use contemplated, the manner of use and whether there
is any infringement of patents is the sole responsibility of the user.
PRINTED IN U.S.A.
4
.A.-25
5M-87B
-------
WAHWtHt frf MJVSWSAl tt&ATIOMS
, DIVISION OF OCCUPATIONAL SAFETY AND HEALTH
131 COtOCH CAT! AV*MVf
lANMANOSCO
AOMIiS UHt 10.
NOH-CODE VESSELS ,,0. tot m
SAM HANCBCO. temperature(s)# cycles, etc.
2. The criteria on which the design is based and all calcula-
tions. The Design and Calculations shall be certified by a
Professional Engineer (competent in the field of Pressure
Vessel Design and registered in the State of California) as
providing safety equivalent to the ASMe Code.
• NOTEj The design shall:
1. Be based on the ASME Code with a factor of safety
of not less than 4, or
2. Provide equivalence to all applicable requirements
' of the ASME Code Section VIII, Division 2.
3. A complete set of drawings including weld details. English
language, U.S.A. units of measurement must be used.
4. A list of all of the pressure boundary materials or those
materials subject to stress as the result of pressure. This
list shall include the material specification used and should
conform to the applicable ASME Standard, or_their suitable
equivalent. If reference is made to a standard or specifica-
tion of a country other than the United States of America*
attach a copy and indicate how the material is considered
equivalent. The stcess values used in all. design calcula-
tions shall not exceed the lower limits shown in the material
specification.
5. Mill test certifications shall be Included for those
materials as required by the ASMS Standard. (English
language, U.S.A. units of measurement)
6. Any welding procedures used in construction and the required
welder's qualification records for those welders used in the
GtOSOt DtUHMOtAN. Cnm
pSXa
A-26
-------
NON-CQDS V6SSSI.S
Page 2 .
fabrication. These procedures and qualification shall be
' made in accordance with ASMS Code, Section IX.
7' All norv-deatxuctive test procedures used and the results of
tests.
6. A> record of the hydrostatic test.^
9. Documentation showing that the quality assurance program used
by the manufacturer, is equivalent to that required by the
Code.
10- The manufacturer of the vessel shall identify the Inspection
Agency whose .personnel wade the shop inspections and signed
the Manufacturer's Data Report for the vessel.
11. Ths qualifications, or Certification by a Jurisdictional
Authority, of the Inspection Agency.
12. Certification by the Inspection Agency that all inspectors
waking shop inspections of the vessel meet the qualificatlons
required by the Jurisdictional Authority. The individual
inspectors names and commission numbers, if any, shall be
provided. The system of supervisorial control oC such inspec-
tors at the shop shall be Included.
13. A "copy of the manufacturer's "traveler" chowing itema
inspected or verified by the shop inspector during fabrica-
tion.
14. A facsimile of the stamped namoplate used on the vessel.
15« A Manufacturer's Data Report, signed by the manufacturer and
the shop inspector, shall be submitted containing the equiva-
lent data required by the ASMS Boiler and Pressure Vessel
Code. (Do not use ASHE Data Report Forms)
When the above information is received, it will be reviewed to
determine whether the vessel can be accepted as meeting the
requirement's of the Safety Orders.
The vessel will be inspected by a qualified Inspector holding m
current California Certificate of Competency at the place of
installation to make certain the above provisions have been
complied with, and that the vessel is identified per the infor-
mation submitted.
St is the prospective owner's responsibility to demonstrate that
the equipment is built and installed and will be operated in
compliance with the Safety Orders administered by this office and
the manufacturer's installation and operational instructions.
6/86
A-27
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CITY OF RIVERSIDE PLXNHXNQ DEPARTMENT ]
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EXHIBIT A
STATEMENT OF WORK
1.0 GENERAL REQUIREMENTS
1.1 SCOPE OF WORK
This statement of work defines the technical and quality assurance requirements for the Contractor to prepare,
demolish, excavate, backfill, form, install, pave, and finish all items specified herein, in accordance with these
Specifications and/or as indicated in the documents listed in Section 1.4, APPLICABLE DOCUMENTS, of this
Statement .of Work. Questions concerning this Statement of Work shall be directed to Acurex Environmental
Corporation (A EC) or to its designated Construction Inspector.
A preconstruction meeting shall be held prior to commencement of any work,
1.2 PROJECT LOCATION, TYPE, AND SITE CONDITIONS
This project is located at CE-CERT, J200 Columbia Avenue, Riverside, CA 92507
The purpose of this project is to prepare the site for a biomass to methanol facility
The Work involves grading and compaction, asphalt, concrete foundations, and fencing.
13 TENANT INTERFACE
The Contractor shall guarantee that all existing structures outside of the work area will not be damaged by his on-site
operations. Any damage to these facilities shall be repaired or replaced by the Contractor at his own expense.
The Contractor must guarantee that the operation of the adjacent facilities will not be adversely affected by operations
of the Contractor at the site.
1.4 APPLICABLE DOCUMENTS
The Work shall be executed in conformance with the documents listed below. If there is, or seems to be, a conflict
between the Drawings or this Specification and a referenced document, the matter shall be referred to A EC in writing
for resolution.
The documents listed shall be of the issue in effect on the date of the Contract and shall form a part of this
Specification. .
Where these documents are not directly referenced in the body of the text, they are intended as basic information
guides and material controls to the work to be done therein, and as such constitute a part of the requirements of this
Specification,
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1.4.1 Standards
A. American Concrete Institute (ACI)
SP-2 Manual of Concrete Inspection
301 Specifications for Structural Concrete for Buildings
305 Hot Weather Concreting
I 306 Cold Weather Concreting
315 Manual of Standard Practice for Detailing Reinforced Concrete
B. American Society for Testing and Materials (ASTM)
A36 Specification for Structural Steel
A82 Specification for Cold-Drawn Steel Wire for Concrete Reinforcement
A185 Specification for Welded Steel Wire Fabric for Concrete Reinforcement
A615 Specification for Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement
C94 Specification for Ready Mix Concrete
D1557 Moisture-Density Relations of Soils and Soil-Aggregate Mixtures Using
10-Pound Rammer and 18-inch Drop
C. Occupational Safety and Health Act (OSHA)
All Standards
D. National Fire Protection Association (NFPA)
All Standards
E. Uniform Building Code (UBC)
Code in total including State of the California Amendments
F. State of California
Department of Transportation Standard Specification Sections 10, 24, 26, 37, 39, 40, 90, 92, 93,
and 94 and Standard Plan Sheets A3S-A and A35-B
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1.4.2 Drawings
The following Drawings are included herein and made a part of this Contract;
Drawing Number
Title
FB-10
COLUMBIA AVE SITE PLAN
B-30Q02
HYNOL PLOT PLAN
XXXXCO01
GRADING PLAN { To Be Determined }
87-9811
TOPOGRAPHICAL MAP
XXXXM001
{ To Be Determined}
It is not intended or to be inferred that the conditions as shown on the above listed Drawings constitute a
representation by AEC, the Owner, or the agents of AEC or the Owner, that such conditions are actually existent,
nor shall the Contractor be relieved of the liability under his Contract, nor shall AEC, the Owner, or any of their
agents be liable for any loss sustained by the Contractor as a result of any variance between conditions as shown on
the Drawings and the actual conditions revealed during the progress of the Work or otherwise.
The Contractor shall check all Drawings furnished him immediately upon their receipt, and shall promptly notify
AEC of any omission or discrepancies. Omissions from the Drawings or the misdescription of Work which are
manifestly necessary to carry out the intent of the Drawings, or which are customarily performed, shall not relieve
the Contractor from performing such omitted or misdescribed details of Work, and they shall be performed as if fiilly
and correctly set forth and described on the Drawings. In case of conflict between the printed text and the Drawings,
the printed text shall govern.
Revisions of the above listed Drawings may be made when deemed necessary by AEC during the progress of the
Work.
1.5 QUALITY ASSURANCE
A. Hold Points
Hold Points shall be mandatory Work stopping points for inspections, testing, or for work to be performed by Others,
which require the Contractor to stop all Work related operations until notified by the AEC Construction Inspector
that Work may again proceed. They may called out in this document under the different technical phases of the
project
B, Deviations and Nonconformances
No deviations from these Specifications will be accepted without prior written approval from AEC. Deviations will
be considered departures from any requirements of these Specifications. Uncorrectable nonconformances are
considered to be conditions which cannot be corrected within these Specifications by rework or replacement. All
deviations or nonconformances shall be communicated to AEC in writing for resolution. Any request for approval
of deviations or nonconformances to the contract documents shall be processed in accordance with CHANGES IN
WORK of the Contract General Provisions (see EXHIBIT B).
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C. Stop Work Action
Where, in the judgment of the AEC Construction Inspector, the Contractor or his subcontractors are performing work
contrary to the conditions and terms of these Specifications, or where continued operations could cause damage,
preclude further inspection, cause injury or loss of life, or render remedial actions ineffective for any product
form/service provided by the Contractor or its subcontractors, the AEC Construction Inspector shall orally notify the
Contractor to stop work and shall confirm such notification in writing within five (5) working days. The Contractor
shall comply with such a notice in accordance with Article 11, "Warranty and Guarantee, Inspections, Correction,
Removal or Acceptance of Defective Work," of the Contract General Provisions (see EXHIBIT B).
D. Tests
Tests to be provided by the Contractor include density and compaction tests for any recompacted existing fill, for
the newly placed fill, and for the aggregate base course.
E, Inspections
The AEC Construction Inspector will be at the site during construction operations. This shall in no way relieve the
Contractor of his responsibility to perform quality work to the limits specified in this document. Therefore, the
Contractor shall take steps to ensure the quality of his work.
1.6 PERMITS
AEC will obtain, pay for, and supply the Contractor with all permits required by local city or county building
departments, planning departments, and'or fire departments.
All other permits required for the construction operations, such as, but not limited to, dumping permits, hauling
permits, etc., shall be the responsibility of the Contractor. The Contractor shall obtain such permits at his own
expense. .
1.7 DOCUMENTATION
The Contractor shall keep, and make available to AEC, records of all operations, equipment, and material movement.
These records shall include, but not be limited to, equipment rental receipts, truck hauling records, landfill receipts,
and all other records needed to assess the extent of the work.
The Contractor shall provide AEC with documentation that any imported backfill material is free of hazardous
chemical contamination (see Section 2.3).
1.8 MEASUREMENT OF PAYMENT
The contract price for the job will become payable upon completion of all work specified herein, demobilization of
all equipment, a satisfactory Final Inspection of the work by the AEC Construction Inspector, and a satisfactory post-
work inspection of the facility by the Owner.
1.9 INSURANCE REQUIREMENTS
The Contractor shall procure and maintain the following insurance coverage at its own expense. Prior to the start
of work, the Contractor shall provide certificates evidencing the insurance coverage and naming Acurex
Environmental Corporation and the Owner, as additional insureds. (See ARTICLE 5 - INSURANCE, in EXHIBIT
B)
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A. Workmen's Compensation Insurance
The Contractor shall procure and maintain Workmen's Compensation Insurance in the amounts required by applicable
state law.
B. Employer's Liability Insurance
The Contractor shall procure and maintain Employer's Liability Insurance in the amounts required by applicable state
law.
C. Comprehensive General Liability Insurance
The Contractor shall procure and maintain Comprehensive General Liability Insurance in the amount of SI,000,000
for bodily injury and property damage,
D. Automobile Liability Insurance
The Contractor shall procure and maintain Automobile Liability Insurance in the amount of $1,000,000 per
occurrence.
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2.0 EARTHWORK
2.1 SCOPE OF WORK
This portion of the Specifications details the technical requirements necessary to complete all earthwork on the
project site, in accordance with the Specifications and Documents. The Contractor shall provide all labor,
supervision, equipment, materials, material disposal, and services to complete all site preparation work, demolition,
shoring, excavation, hauling, filling, and finishing work. The following sections detail the requirements for each type
of work.
2.4 SITE PREPARATION 2.7 EXCAVATION
2.5 DEMOLITION 2,8 AREA FILL, BACKFILL,
2.6 SHORING GRADING, AND COMPACTION
2.2 GENERAL REQUIREMENTS
All equipment and material shall be furnished and installed in accordance with the General Requirements.
The Contractor shall keep a copy of any construction drawings at the site at all times during his operation.
The Contractor shall provide adequate shoring, bracing, guys, and safety barriers in accordance with all national,
state, and local safety codes and ordinances. Any deviation must be approved by AEC prior to beginning any
excavation work. Such approval is required solely to inform AEC of the situation, and shall not be deemed to shift
the responsibility for the adequacy or correctness of the situation from the Contractor.
The Contractor shall be solely responsible for all excavation procedures including lagging, shoring, and protection
of adjacent property, structures, streets, and utilities, in accordance with all national, state, and local construction or
safety codes and ordinances.
The Drawings indicate general and typical arrangement of areas of construction. Where conditions are not
specifically indicated but are of similar character to arrangement shown, similar details of construction may be used,
subject to review by the AEC Construction Inspector.
The Contractor shall limit disturbances to the site to the minimum necessary to complete the work. Structures, roads,
parking areas, vehicles, and vegetation adjacent to the excavation site and hauling route shall be protected to the
satisfaction of AEC and the Owner. Should any structure or material be damaged by the operations of the
Contractor, the Contractor shall correct such damage at his own expense. The Contractor shall restore all disturbed
areas not a part of the completed work to a condition as near to the original condition as possible. The Contractor
shall be held liable for any damages to vehicles or personal property occurring as a result of the Contractor's
operations at the site.
During excavation and filling phases, all public streets adjacent to the project shall be kept clean and free of all
material deposits resulting from the operation.
The Contractor shall provide the means for preventing or lessening all dust nuisances and damages. Such means may
include, but not necessarily be limited to, applying water, dust palliatives, or both, in accordance with local
ordinances and regulations.
The Contractor shall provide temporaiy erosion control measures for excavation, storage, and backfill operations at
the site. They may include, but not be limited to, covering all,excavated soil with plastic sheeting and positioning
hay bales around the periphery of the excavated soil.
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23 MATERIALS AND EQUIPMENT
The Contractor shall furnish all tools, equipment, materials, and services necessary or required for the completion
of the work in accordance with the Contract
Temporary Tojlet facilities for all workmen shall be provided and maintained by the Contractor through completion
of the Work.
The Contractor shall provide ail water for construction purposes such as dust control and compaction. Drinking
water for the workmen shall be provided by the Contractor.
All other utilities required for use in the Work shall be provided and maintained by the Contractor.
All new fill material shall be free of chemicals, hazardous materials, and hazardous waste contamination. The
Contractor, or an agent of the source of the fill material, shall provide AEC with documentation that the fill material
is free from contamination. The Contractor shall submit the name of the source and a description of the proposed
fill material to AEC for approval prior to beginning the work.
23.1 Fill Material
Type"A" Material: Top soil obtained from site excavations from existing surface to 9-inches deep.
Type "B" Material: Moderately to highly expansive soils consisting of the more cohesive, stiff, and highly
plastic clays and clayey to cemented silts. The material shall be completely free from wood, roots, and other
extraneous material, and shall not contain any rubble, clods, or rocks over 3-inches in greatest dimension.
Type "C" Material: Non-expansive subsurface soils consisting of all silts and sands which are free of
vegetation, rubble, or other deleterious substances, having no clods or particles larger than 3-inches in maximum
dimension, and which have a plasticity index not exceeding 12.
Type "D" Material: Select structural backfill material meeting all the qualifications of Type "C" Material,
but comprised of non-plastic sands.
Type "EM Material: Clean, granular material free from organic matter and conforming to the following
gradation:
SIEVE SIZE PERCENT PASSING
- 1-inch 100
No. 4 0-5
Type *FH Material: Clean, free draining, granular materia] free from organic matter and conforming to the
following gradation:
SIEVE SIZE PERCENT PASSING
1-inch 100
No. 4 0
Type "G" Material: Clean sand of good quality and in accordance with U.B.C. Chapter 70, Section 7010(d).
Type "H" Material: Clean aggregate base course material conforming to the requirements of California
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Specification Section 26 for Class 2 aggregate base, 3/4-inch maximum size.
Type "J" Material: Clean, washed, sound and durable, well graded crushed rock, crushed gravel or gravel
of 1-1/2-inch maximum size and 3/8-inch minimum size.
Type "K" Material: Clean, washed, sound and durable 1/4-inch pea gravel.
NOTE: No Type "E" or Type "F" material shall be used until it has been accepted by the AEC Construction
Inspector. Samples of the material proposed for use shall be submitted a sufficient time in advance of its intended
use to enable its inspection and testing.
2.4 SITE PREPARATION
Site preparation requirements for this project { To Be Determined J
If the Contractor requires temporary storage area, the AEC Construction Inspector will arrange for such storage space ---
at the site.
All topsoil and vegetation such as roots, brash, heavy sods, heavy growths of grass, and all decayed vegetable matter,
Tubbish and other unsuitable material shall be stripped or otherwise removed from the natural surfaces of the plant
area fills. Topsoil (Type "A" fill material) shall be stockpiled for use in the upper 6-inches of all landscaped areas.
Ni All stripping shall be disposed of by the Contractor in a manner acceptable to the AEC Construction Inspector. After
topsoil and vegetation have been removed, the areas to receive fill material shall be proof-rolled with a heavy roller
to locate any zones that are soft or spongy. If weak soils are detected they shall be replaced with properly compacted
filL .
2.5 DEMOLITION
Demolition shall involve { To Be Determined}
The Contractor shall furnish all labor, equipment, supervision, hauling, and service to complete the demolition work
shown on the Drawings.
Demolition must not proceed until any and all required permits have been obtained.
2.6 SHORING
The use of shoring is at the Contractor's discretion. However, any damage resulting to the equipment or structures,
due to failure of the soil or by any other action of the Contractor, shall be the sole responsibility of the Contractor.
The Contractor shall indemnify AEC and the Owner against any loss resulting from any damage caused by the
Contractor's operations.
2.7 EXCAVATION "
The Contractor shall provide all labor, equipment, supervision, and hauling necessary to remove the soil and dispose
of it in an approved landfill or AEC approved disposal site.
AEC shall provide a drawing of the excavation limits and shall provide inspection of the operation.
Except as otherwise shown or specified, any method of excavation within the work limits shown may be employed
which, in the opinion of the Contractor, is considered workable. Existing paving, underground piping, adjacent
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structures and/or property shall be protected at all times from damage of undermining, uneven settlement, and impact
The Contractor shall take care not to disturb the natural or fill soils at, below, or adjacent to the excavation.
The excavation shall be kept free of water. The Contractor shall provide and operate all equipment necessary to
accomplish this, and shall set-up diversion channels to aid in this respect should inclement weather become a
possibility.
Dust, erosion, and noise shall be controlled at the site. The Contractor shall control dust emissions to the maximum
extent possible. Water used for dust control shall be free of contamination.
Hauling shall be done during normal daylight working hours to prevent adverse effects upon all neighborhoods along
the haul route. The Contractor shall restrict site construction operations to normal daylight working hours to
minimize adverse effects of noise on the surrounding community. Hauling shall be in compliance with any
regulations or codes established by any municipalities having jurisdiction at the site or along the haul route. The
Contractor shall consult those municipalities to obtain any needed permits to accomplish the hauling phases of the
project
/¦
Where necessary, the Contractor shatl provide for erosion control. Such provisions shall be in conformance with
all local codes and ordinances, and to the satisfaction of the AEC Construction Inspector.
The excavation shall only be carried on to the limits as shown on the Drawing. If further material is removed
without prior approval by AEC, the Contractor shall replace the extra cut material at his own expense. Any
additional fill material made necessary by the Contractor's operations shall be paid for by the Contractor.
In addition to the Fixed Price Bid submitted by the Contractor in response to this Contract, the Contractor shall
provide Acurex with an hourly Time and Material price for additional excavation and fill beyond the limits and scope
shown on the drawings. This price will be used as a basis for any AEC approved Change Orders increasing the
scope of the excavation work.
2.7,1 At Structures
Except as otherwise shown or specified, any method of excavation within the work limits shown may be employed
which, in the opinion of the Contractor, is considered best. At those locations where the excavation extends below
the static groundwater level, or the natural soils are saturated and of low strength, the Contractor shall take whatever
precautions are necessary to maintain the undisturbed state of the foundation soils at and below the bottom of the
excavation.
Material shall not be stockpiled to a depth greater than 5-feet above finished grade within 75-feet of any excavation
or structure. However, it shall be the Contractor's responsibility to maintain stability of the soil adjacent to any
excavation.
Where, in the opinion of the AEC Construction Inspector, the undisturbed condition of the natural soils below the
excavation grades indicated or specified is inadequate for the support of the planned structure, the AEC Construction
Inspector shall direct the Contractor to over-excavate to adequate supporting soils and refill the excavated space to
the proper elevation in accordance with the procedure specified for backfill, or if under footings, refill the space with
concrete. The quantity and placement of such material shall be as ordered by the AEC Construction Inspector and
shall be paid for as extra work.
Should the excavation be carried below the lines and grades indicated on the drawings because of the Contractor's
operations, the Contractor shall, at his own expense, refill such excavated space to the proper elevation in accordance
with the procedure specified for backfill or, if under footings, the space shall be filled with concrete as directed by
the AEC Construction Inspector Should the natural foundation soils be disturbed or loosened because of the
Contractor's operations, they shall be recompaeted or removed and the space refilled as directed by the AEC
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Construction Inspector at the Contractor's expense.
Excavation shall extend a sufficient distance from walls and footings to allow for placing and removal of forms,
installation of services, and for inspection, except where concrete is authorized to be deposited directly against
excavated surfaces. Existing structures which remain as part of the final construction shall be protected at all times
from damage of undermining and uneven settlement.
Where pipelines and sewere enter a structure, the requirement for trench excavation shall be complied with up to the
excavation line of the structure unless specified or directed otherwise.
2,7.2 At Pipelines. Sewers, and Electrical Conduits
Unless otherwise indicated, excavation for pipelines and sewers shall be open cut. Trenching machines may be used
except where their use will result in damage to existing facilities. Unless otherwise specified or indicated, the
Contractor may use any method of excavation which will not damage or endanger adjacent structures or property
or disturb the natural or fill soils at, below and adjacent to the excavation.
When additional gravel or crushed rock is required to stabilize a soft, wet, or spongy foundation caused by the
operations of the Contractor, such gravel or crushed rock shall comply with Type "J" material for both material and
placing, and shall be provided at the Contractor's expense.
All trenches shall be excavated a minimum of 6-inches below the barrels of pipes 4-inches and larger and 2-inehes
minimum for pipes smaller than 4-inches. Bell holes shall be excavated as necessary to provide above clearances.
To suit field conditions, excavation below the depths shown or indicated herein may be ordered by the AEC
Construction Inspector. Unsuitable material shall be removed and replaced with Type "J" material. Excess
excavation and fill ordered by the AEC Construction Inspector will be paid for as extra work.
The maximum allowable width of trench measured 6-inches minimum above the top of the pipe shall be the pipe
outside diameter exclusive of bells and collars plus 18-inches, or as shown on the drawings, and such maximum
width shall be inclusive of all wench bracing, shoring and timbers. A minimum of 8-inches shall be maintained
between pipe and trench wall or sheeting. Where pipes are placed in a common trench, a clear distance between
pipes shall be maintained to allow backfill to be properly compacted with a minimum distance of 12-inches unless
otherwise directed by the AEC Construction Inspector, or shown on the drawings.
At manholes, the maximum trench width shall be increased to provide at least 18 inches clear distance around the
outside of the manhole.
Whenever the maximum allowable trench width is exceeded for any reason, the Contractor shall, at his expense,
embed or cradle the pipe in concrete in a manner acceptable to the AEC Construction Inspector or provide evidence
that the pipe can safely carry the additional loading imposed by the increased trench width .
In accordance with the requirements of Section 6750 of the Labor Code of the State of California, the Contractor
shall submit a detailed drawing to the AEC Construction Inspector before excavation, showing the design of shoring,
bracing, sloping or other provisions to be made for worker protection from the hazard of caving ground during the
excavation of any trench or trenches 5-feet or more in depth.
The minimum required protection will be that described in the Construction Safety Orders of the Division of
Industrial Safety. If the Contractor presents a drawing which varies from the shoring system standards established
by the Construction Safety Orders, the drawing shall be prepared and signed by a registered civil engineer.
The AEC' Construction Inspector will review the drawing submitted by the Contractor and return it with comments
indicating unacceptable deficiencies; however, the Contractor shall be responsible for the adequacy of the design.
Said review will be to assure AEC and the Owner of general compliance with the Labor Code and Safety Orders
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and shall not be construed as a detailed analysis for adequacy of the support system, nor shall any provisions of the
above requirements- be construed as relieving the Contractor of overall responsibility and liability for the work.
The Contractor shall not start excavation until after the trench support drawing has been returned by the AEC
Construction Inspector.
In addition, the Contractor shall obtain, pay for, and comply with all provisions of the permit required by Section
6500 of the California Occupational Safety and Health Act
2.8 AREA FILL, BACKFILL, GRADING, AND COMPACTION
The Contractor shall provide all labor, equipment, material, supervision, and services to complete the hauling, filling,
grading, and compacting operations.
Except as otherwise shown or specified, any method of backfilling within the work limits shown may be employed
which, in the opinion of the Contractor, will provide the necessary compaction while not damaging adjacent
structures or equipment The Contractor may use any method of backfilling which will not damage or endanger the
adjacent structures, piping, paving, or property adjacent to the work site.
Compaction where used below is defined as relative compaction and refers to the in-place dry density of the fill
expressed as a percentage of the maximum dry density of the same material, as determined by the ASTM D1557
laboratory test procedure. In addition to required compaction tests provided by the Contractor, all compacted
materials may be tested by the AEC Construction Inspector by in-place moisture and density tests. Excavations
within 5-feet of, or under, structures shall be treated as structural excavation and backfill.
As used in this specification, the following definitions shall apply:
"Engineered Fill" means ali fill placed within areas supporting buildings, structures, equipment
slabs, roadways, and all paved areas, walk-ways and slabs on grade. Limits of engineered fill shall
extend 2-feet beyond foundations of structures and edges of roadway or paved areas and to
thickness as shown on the drawings.
"Embankment Fill" means all fill used in construction of dikes and embankments.
"Site Fill" means fill placed in all areas except the engineered fill and embankment fill.
2.8.1 Area Fill
Area fill and grading includes all fill, other than structural backfill, required to bring the site to finished elevations
as shown.
Areas receiving fill shall be scarified to a depth of 6-inches, brought to a moisture condition at least 4 percent over
optimum moisture, if a clay subgrade, or to optimum moisture content, if a non-expansive subgrade, and shall be
recompacted in place to at least 90 percent of the ASTM D1557 maximum diy density (clay subgrade) or 95 percent
compaction (non-expansive subgrade). Site fill areas shall be compacted to at least 85 percent of maximum dry
density.
Engineered Fill; Material for engineered fill shall be Type "C" or Type "D" material and shall be spread in layers
not exceeding 6-inches loose thickness. Each layer shall be compacted to 90 percent of maximum diy density for
fill 3-feet below the finished grade, and to 95 percent of maximum diy density for the top 3-feet.
Embankment Fill: Material for embankment fill shall be Type "B" material or a blend of Type "B" and Type "C"
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materials and shall be spread in layers not exceeding 6-inches loose thickness. Each layer shall be compacted to at
least 90 percent of maximum dry density. When, in the opinion of the AEC Construction Inspector, the surface of
any compacted layer is too smooth to bond properly with the succeeding layer, it shall be scarified to the satisfaction
of the AEC Construction Inspector before the succeeding layer is placed thereon.
Site Fill: Material for remaining site fill shall be Type "B", Type "C" or Type "D" material. Material shall be
compacted to at least 85 percent of maximum dry density.
2.8.2 At Structures
Fill Under Slabs: After the subgrade has been prepared, areas under all slabs in contact with earth shall receive a
fill of either Type "J" or Type "F" fill material. Fill material shall be as specified. Structural base slabs shall be
underlaid with Type "J" material. All other slabs on grade shall be underlaid with a layer of Type *F" or Type "J"
material. The Type "F" or Type "J" material shall be compacted to 95 percent of maximum dry density and shall
have a thickness, after compaction, of not less than 6-inches, or as shown on the drawings.
When Type "J" material is to be placed beneath base slabs, the Type "J" material shall be compacted by vibratory
equipment. Where acceptable to the AEC Construction Inspector, the Contractor may substitute a suitable tractor
or equivalent for vibratory compaction equipment. In that event compaction shall be accomplished by making two
passes across the entire width of the drainage layer with the tractor operated at high speed; each pass giving complete
coverage with the tractor treads.
All fill material under buildings, structures, equipment slabs, roadways, paved areas, walkways and slabs-on-grade
shall be engineered fill, whether shown on the drawings or not. Engineered fill material and placement shall be as
specified in this section of the specifications.
Replacement of Expansive Material Under Slabs, Foundations, and Pavements: Where expansive clays (Type "B"
material) are encountered under structures, buildings, concrete slabs, roadways, and paved areas, the clay material
shall be removed and replaced with Type "C" or Type "D" fill material as required to assure compliance with the
following criteria:
At least 24 inches of Type "C" or Type "D" fill material plus 6-inches of Type "F" material shall be provided
beneath the undersurface of floor slabs, exterior concrete slabs and similar items. At least 12-inches of Type "D"
fill material shall be provided beneath shallow building foundations. At least 12-inches of Type *C" or "D" fill
material shall be provided below the Type "H" material within asphalt concrete pavement areas to provide a higher
quality subgrade than expansive clays.
Type "D" fill material supporting building foundations shall be compacted in horizontal lifts no thicker than 6-inches
in compacted thickness with each lift being uniformly compacted to at least 95 percent compaction as defined above.
Type "C" or Type "D" fill materia] supporting slabs and asphalt concrete pavement shall be placed in 6-inch layers
and uniformly compacted to at least 90 percent for concrete slabs and 95 percent for asphalt concrete pavement.
Structures; After completion of foundation footings and walls and other construction below the elevation of the final
grade, and prior to backfilling, all forms shall be removed and the excavation shall be cleaned of all debris. Unless
otherwise shown, backfill shall be Type "D" material compacted to 90 percent of maximum dry density.
An impervious barrier shall be provided at the top of wall backfill to prevent infiltration of surface runoff water
alongside walls. The barrier shall consist of asphalt paving, concrete, or at least 2-feet of Type "B" backfill
compacted to 90 percent of maximum dry density.
The Contractor shall not proceed with backfill placement in excavated areas until acceptance is received from the
AEC Construction Inspector. To determine if the Contractor is obtaining compacted backfill which will meet the
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specified requirements, frequent moisture content and density tests will be taken by the Contractor during these
operations.
Backfill material shall be placed in uniform horizontal layers not exceeding 6-Inches in loose depth and shall have
a moisture content such that the required degree of compaction can be obtained. The thickness of the loose layer
may be increased when in-place density tests, satisfactory to the AEC Construction Inspector, show that the specified
density can be obtained throughout the layer. Light construction equipment shall be used within S-feet of structures
to avoid overstressing the walls.
The Contractor shall maintain the surface of the backfill to prevent ponding water or collection of surface runoff and
subsequent saturation of compacted or uncompacted layers. During inclement weather, the Contractor shall control
surface runoff in such a manner so as to prevent erosion of the backfill or slope surfaces.
All retaining walls shall be backfilled on the earth side with Type "J" material.
2.8.3 At Pipelines. Sewers, and Electrical Conduits
Bedding: All pipes shall have a minimum of 2-inches of bedding material below the barrel of the pipe unless noted
otherwise on the Drawings. Bedding material shall be Type "E" material and shall be shaped around the barrel of
the pipe. Plastic piping shall have a bedding of Type "G" or Type "K" material with a depth below the pipe of 1/3
the pipe diameter but not less than 2-inches. Bedding shall be compacted to 95 percent of maximum dry density.
Where stabilization of the undisturbed foundation below the bedding is required because of soft, spongy, or unstable
condition, Type "J" material shall be placed in the trench bottom. The quantity and placement of such material shall
be as directed by the AEC Construction Inspector and will be paid for as extra work.
Initial Backfill: After the pipe has been properly laid and inspected, Type "D" material shall be placed around the
pipe to a depth of 6-inches minimum over the pipe. The initial backfill material shall be placed in uniform
horizontal layers not exceeding 6-inches in loose depth and compacted to a dry density of 95 percent of maximum
dry density. Where compaction is done by jetting (if allowed be the AEC Construction Inspector), the thickness of
each layer shall not exceed 4-feet. Material other than Type "D" will be permitted only after obtaining approval of
the AEC Construction Inspector.
Each layer shall be compacted to the specified density prior to placing subsequent layers. The thickness of the loose
layer may be increased when in-place density tests, satisfactory to the AEC Construction Inspector, show that the
specified density can be obtained. No further backfilling will be permitted until the initial backfill has been accepted
by the AEC Construction Inspector.
Subsequent Backfill: Backfill shall not be deposited in the trench in any manner which will damage or disturb the
pipe or the initial backfill. Above the level of initial backfill, the trench shall be filled with Type "C" or Type "D"
material unless otherwise indicated. The backfill material shall be placed in uniform horizontal layers not exceeding
6-inches in loose depth and shall have a moisture content such that the required degree .of compaction can be
obtained. Each layer shall be compacted to a dry density equal to 90 percent of maximum dry density as determined
by the ASTM D1557 laboratory test procedure. Hie thickness of the loose layer may be increased when in-place
density tests, satisfactory to the AEC Construction Inspector, show that the specified density can be obtained
throughout the layer.
Compaction by jetting may be permitted when, as determined by the AEC Construction Inspector, the backfill
material is of such character that it will be self-draining when compacted and that foundation materials will not
soften or otherwise be damaged by the applied water and no damage from hydrostatic pressure will result to the pipe.
The thickness of each layer prior to jetting shall not exceed 4-feet. Jetting of the upper 4-feet below finish grade
will not be permitted. Jetting method shall be supplemented by the use of other compaction equipment when
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necessary to obtain the required compaction.
The grading and compaction will be considered complete when the fill has been properly compacted and has been
finished-off at the proper subgrade level.
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3.0 MECHANICAL
3.1 SCOPE OF WORK
This portion of the Specifications details the technical requirements necessary to complete all mechanical work on
the project site, in accordance with the Specifications and Documents, The Contractor shall provide all labor,
supervision, equipment, materials, material disposal, and services to complete all site mechanical work.
AEC shall fkmish the following pre-purchased equipment items for installation by the Contractor.
Item
Quantity
Description
3
2
?
{ To Be Determined }
{ To Be Determined }
{ To Be Determined }
5
4
?
?
{ To Be Determined }
{ To Be Determined }
6
?
{ To Be Determined }
{ To Be Determined }
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4.0 CONCRETE WORK
4.1 SCOPE OF WORK
The Contractor shall furnish all labor, supervision, equipment, materials, formwork, vertical and horizontal survey
control, testing, and services to provide a concrete slab-on-grade over the existing methanol product tank. A plan
view and typical cross sections are shown in the Drawings.
4.2 FORMWORK
Forms shall be smooth, mortar tight, true to the required lines and grade, and shall conform to the Drawings to shape,
line, and dimensions of members. The forms shall have sufficient strength and rigidity to hold the concrete and to
withstand the necessary pressure, tamping, vibration, and construction loads without deflection or springing out of
shape during the placing of concrete. The formwork shall provide total support for all embedded metal. All metal
items indicated for embedding in the concrete, shall be accurately placed, cleaned, and securely fastened to the
formwork prior to placement of the concrete. All support for embedded items shall be from the formwork. No
additional items shall be embedded after placing of concrete. The Contractor shall assume full responsibility for the
adequate design and erection of all forms. Forms shall be inspected by the AEC Construction Inspector prior to
concrete placement, and if, in the opinion of the AEC Construction Inspector, they are unsafe or inadequate in any
respect, they shall be reworked or adequately replaced by the Contractor at the Contractor's expense. All lumber
for use as formwork, shoring, or bracing shall be new, or of adequate strength and surface quality, for the task at
hand. Hie Contractor may use the most advantageous panel size and joint locations. Neat patches and minor surface
imperfections will be permitted. All exposed edges of concrete on both the inside and outside of structures shall be
chamfered or beveled at an angle of 45 degrees, such bevel being 3/4-inch on each side. All exposal horizontal
concrete edges shall have a 1/2-inch radius tooled in the wet concrete during the finishing operation .All chips,
sawdust, and other foreign matter shall be removed from the formwork before any concrete is deposited therein.
Before concrete is deposited within the forms, all inside surfaces of the forms shall be thoroughly coated with an
AEC approved form sealer. Excess form coating material shall not be allowed to stand in puddles in the forms.
Forms, bracing, and shores shall be kept in place until removal is accepted by the AEC Construction Inspector, and
in no case shall concrete formwork be removed earlier than 48 hours after placement of concrete. Forms shall not
be stripped from concrete which has been placed in ambient temperatures under SO'F without first determining if
the concrete has properly set.
4.3 CONCRETE REINFORCING STEEL
Reinforcement bars shall be deformed bars conforming to ASTM A615 and shall be Grade 40,40,000 psi minimum
yield strength. Wire-shall conform to ASTM A82, Welded wire fabric for concrete reinforcement shall conform
to ASTM A18S, except that the weld shear strength requirement of Section 5b of those specifications shall be
extended to include a wire size differential up to and including No, 6 gage. Supports for reinforcing bars in concrete
slabs-on-grade shall be precast concrete blocks. Metal or plastic support legs shall not be used.
Steel reinforcement may be fabricated in the shop or in the field. All fabrication shall be in accordance with ACI
315, except as otherwise specified. Steel reinforcement for stirrups and tie bars shall be formed around a pin having
a minimum diameter of 3 bar diameters. All other reinforcing steel shall be formed around a pin having a minimum
diameter of 8 bar diameters. All bars shall be bent cold.
Before the bars are placed, the surfaces of the bars shall be cleaned of heavy flaked rust, loose mill scale, dirt, grease,
or other foreign substances which are objectionable in the opinion of the AEC Construction Inspector. The
reinforcement bars shall be kept in a clean condition after placement until they are embedded in the concrete.
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Reinforcement bare shall be accurately placed and secured in a position so that they will not be displaced during the
placement of the concrete, and special care shall be exercised to prevent any disturbances of the reinforcement bars
in concrete that has already been placed. Straightening or rebending improperly bent bars will not be allowed.
Heating or welding or bars will be permitted only upon specific approval of the AEC Construction Inspector.
Measurements for bending and placing the bars, except for hooks and clearances, shall be to the centerline of the
bars.
AH splices of the bars shall be lapped splices conforming to the requirements of ACI318, Field splices in locations
other than those shown on the Drawings shall be designed in accordance with ACI 318. Adjacent sheets of welded
wire fabric shall be spliced by lapping not less than one mesh pattern plus 2-inches (6-inch minimum); the lapped
ends being securely wired or clipped together with standard clips.
The minimum cover for main reinforcement shall conform to the dimensions indicated on the Drawings, or shall be
as shown below. The dimensions listed below indicate the clear distance from the edge of the main reinforcement
to the concrete surface.
1. Formed concrete exposed to weather and/or in contact with soil:
(a) No. 6 bars and larger 2-inches
(b) Ho. 5 bars and smaller 1-1/2-irxhes
2. Unformed concrete in contact with soil:
(a) All bar sizes 3-inches
Material improperly detailed or wrongly fabricated so that erection in the field necessitates extra work shall be the
responsibility of the Contractor. The Contractor shall repair or replace, at his own expense, any part of the material
proving defective in fabrication or damaged in shipment.
4.4 CONCRETE
All concrete shall be Portland Cement Type I concrete and shall have a 28-day compressive strength of 3000 psi,
2 to 3-inches of slump, and 1-inch maximum aggregate size. Minimum cement content shall be 5-1/2 sacks per cubic
yard.
Scheduling for delivery of concrete shall be the responsibility of the Contractor. Equipment for transporting concrete
shall be in accordance with provisions of ASTM C94 for ready-mixed concrete. Any concrete ftirnished by the
Contractor which is allowed to become too stiff for effective placement or consolidation during transportation or
conveying to the placement site shall not be used for construction.
Before placing concrete, the forms, reinforcing steel, and all other embedded items shall be approved by the AEC
Construction Inspector for position, stability, and cleanliness. Concrete shall be deposited continuously so that the
unit will be monolithic in construction. The concrete shall be worked into the comers and angles of the forms and
around all reinforcement and embedded items without permitting the component concrete materials to segregate.
Adequate equipment for handling and placing concrete containing the maximum aggregate size and low-slump
concrete mixes shall be provided. Concrete shall be deposited as close as possible to its final position in the forms
so that free'drop flow within the mass does not exceed 5-feet, and consequent segregation is reduced to a minimum.
Adequate protection shall be available to protect the concrete from sudden rain storms, from the sun and dry winds
in the summer months, and freezing in the winter months.
Surfaces of soil upon which concrete is to be placed shall be clean and free from oil, standing or running water, mud.
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objectionable coatings, and debris. All surfaces shall be wetted before placing concrete.
Concrete shall be placed with the aid of mechanical vibrating equipment and supplemented by hand spading and
tamping. The vibrating equipment shall be of the internal type and shall at all times be adequate in number of units
and power of each unit to properly consolidate all concrete. The frequency of vibration shall not be less than 6,000
cycles per minute, submerged in concrete. The duration of vibration shall be limited to that necessaiy to produce
satisfactory consolidation without causing objectionable segregation. In consolidating each layer of concrete, the
vibrator shall be operated in a near vertical position, and the vibrating head shall be allowed to penetrate under the
action of its own weight and re-vibrate the concrete in the upper portion of the underlying layer. Neither form nor
surface vibrators shall be used. Vibrators shall not be used to move or spread concrete. Not less than one spare
vibrator in good working condition for each placement shall be kept available for immediate use at the placement
location; provisions shall be made for auxiliary power to provide continuity of vibration in case of power failure
from the principal source. An experienced and competent operator shall be provided' for each vibrator being used.
Concrete shall be placed before initial set has occurred and before it has contained its water content for more than
60 minutes or received truck agitation in excess of 300 revolutions.
When the ambient temperature is 40" F or below, cold weather precautions shall be taken per ACI 306. When the
ambient temperature is 80* F or above, hot weather precautions shall be taken per ACI 305.
Finished slab surfaces shall be true plane surfaces, within a ± 1/8-inch tolerance in 10-feet unless otherwise shown
on the Drawings. Surfaces shall be pitched to drain as shown on the Drawings. The dusting of finish surfaces with
dry materials will not be permitted. The finished slab shall be steel trowel finished by tamping the concrete with
special tools to force to coarse aggregate away from the surface, then screeding and floating with straight edges to
bring the surface to the required finish level. While the concrete is still green, but sufficiently hardened to bear a
persons weight without deep imprint, it shall be floated either by hand or mechanical means to a true, even plane
with no coarse aggregate visible. Sufficient pressure shall be used on the float to bring moisture to the surface.
After surface moisture has disappeared, the surface shall be hand troweled to a smooth, even finish. Trowel marks
shall be removed by hand steel troweling. Top edges of slabs shall have a 1/2-inch radius tooled into the wet
concrete during finishing operations. After the final steel troweling, the surface shall receive a light broom finish.
All fresh concrete shall be adequately protected from the weather and sun, and from mechanical injury, until
thoroughly set and of sufficient strength to prevent damage. The Contractor shall apply a coating of membrane
curing compound. Membrane curing shall be by the use of Hunt's Process impervious membrane, or AEC approved
equal, applied in two coats at a rate of not less than I-galion to 300 square feet of surface area per coat. The curing
liquid shall have a temporary color sufficient to indicate the extent of its application. It shall finally form a hard,
colorless surface within 30-minutes. The application of the compound shall commence immediately after finishing
operations are completed; provided that in the event application of the compound is delayed, the concrete surface
shall be kept continuously moist until the compound is applied. The compound shall be sprayed on the concrete
surfaces by approved equipment having separate lines to the nozzle for material and for compressed air. Precautions
shall be taken by the Contractor to avoid damage to the coatings for a period of not less than 10-days. Any such
damage shall be repaired immediately by, and at the expense of the Contractor, to the satisfaction of the AEC
Construction Inspector. Curing compound shall not be diluted by addition of solvents or thinners or altered in any
manner.
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5.0
SITE PAVING
5.1 SCOPE OF WORK
The Contractor shall furnish all labor, supervision, equipment, materials, material disposal, and services to provide
all site paving work.
Areas to be paved shall include the excavation area shown in the Drawings, and any paved areas damaged by the
Contractor's operations at the site, ,
5.2 MATERIALS
The paving materials used shall match as closely as possible the existing pavement section. Deviations from these
Specifications shall be subject to approval by AEC.
The materials for the paving work shall include a prime coat, a tack coat, asphaltic concrete, and an asphalt emulsion
fog seal coat. Quality and grading for aggregate base course shall conform to the requirements specified in Section
2.3, MATERIALS AND EQUIPMENT, and as installed according to Section 2.8, AREA FILL, BACKFILL,
GRADING, AND COMPACTION, above.
{
The prime coat shall consist of a coating of liquid asphalt, Grade MC-250, conforming to California Specification,
Section 93 or a coating of SS-1H asphalt emulsion conforming to California Specification, Section 37.
The tack coat shall consist of a coating of asphaltic emulsion, Grade RS-1, conforming to California Specification,
Section 94.
Asphaltic concrete shall be proportioned in accordance with California Specification, Section 39, using Type B
mineral aggregate, 1/2 in. maximum size as specified.
Asphalt binder shall be paving asphalt, Grade AR4Q0Q, conforming to California Specification, Section 92.
The asphalt emulsion fog seal coat shall be SSI type asphaltic emulsion conforming to California Specification,
Section 37.
53 INSTALLATION
Prime Coat: The prime coat shall be applied to the base course in a continuous film, at a rate of 0.25 gallons per
square yard for Grade MC-250 liquid asphalt, or 0.05-gallons per square foot for SS-1H asphalt emulsion, in
conformance with California Specification, Section 39-4.
Tack Coat: A continuous tack coat shall be applied to the edges of existing asphaltic concrete, in conformance with
California Specification, Section 39-4, to ensure a good bond between the old and new asphalt.
Asphaltic Concrete: Asphaltic concrete surfacing shall be spread and compacted in conformance with California
Specification,'Section 39. No asphaltic concrete surfacing shall be placed until the other construction work is
completed. No pavement shall be placed when the atmospheric temperature is below 40' F. Total asphaltic concrete
depth shall match existing paving except that in no case shall the depth be less than 2-inches.
Wherever possible, the asphaltic concrete paving shall be spread with a self-propelled paving machine, towed
spreader, or tractor and spreader bar. Any irregularities in toe surface shall be corrected directly behind the paver.
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Excess material shall be removed immediately. Casting of mix over the paved area shall not be permitted. Any
method of spreading asphaltic concrete which produces segregation or non-uniformity of texture of the surface shall
not be used. Asphaltic concrete shall not be placed or rolled at an asphalt temperature less than 180" F,
The asphalt surfacing shall be sloped as shown or as required to match the existing grade, and to ensure that there
will be no ponding. Maximum variations in finished surface of the asphalt concrete shall be ±l/4-inch in 10-feet
Asphaltic concrete shall be rolled with a minimum 8-ton tandem steel wheeled power roller. Rolling shall commence
as soon as possible after spreading the hot mix, so that it can be compacted without displacement Rolling shall
continue until thoroughly compacted and all roller marks have been removed. In arm too small or to close to
adjacent structures for power rolling, a small roller, vibrator, or hand tamper shall be used to achieve thorough
compaction. The Contractor shall take care in rolling and compacting operations not to damage any other Work in
place. Any such damage shall be repaired at the Contractor's expense to the satisfaction of the AEC Construction
Inspector.
The Contractor shall provide all necessary surveying equipment (transit, level, etc.) to ensure that the above
requirements are adhered to..
AH concrete edges and cutoffs shall be struck and left in a clean, straight line. No asphaltic concrete shall overlap
concrete pads, slabs, or walkways.
Fog Seal: A fog seal coat shall be applied over all new asphaltic concrete surfaces in accordance with California
Specification, Section 37.
It shall be the Contractor's responsibility to provide required testing of the materials used to verify that the materials
do comply with the minimum requirements of these Specifications. The results of this testing shall be submitted to
AEC for approval. AEC may conduct independent testing of materials and final pavement for verification of
compliance at its own discretion. Such tests will be available for the Contractor's review, but will not relieve him
of the responsibility of performing his own tests.
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6.0 SITE SAFETY. SECURITY. AND CLEANUP
6.1 SArETY
During the construction period, the Contractor shall be responsible for the safety of the operation. The Contractor
shall require all employees, sub-contractors, suppliers, etc., performing work for the Contractor, to adhere to all
national, state and local safety laws and regulations in the performance of the Work.
6.2 SECURITY •
The Contractor shall be responsible for the security of the site from start to finish of his operations. Should the
Contractor decide to install a system of temporary fences and gates for the purpose of maintaining a security system
during construction, he shall do so at his own expense. The design and location of the fencing is up to the
Contractor and shall be subject to approval by AEC. The Contractor may want to enclose an area that would provide
security for his equipment. The fencing system used must not disturb the operations of tenants in the area during
their business operations.
63 COMPLETION AND CLEANUP
At the completion of the Work, the Contractor shall remove all temporary services, facilities, hay bate, construction
equipment, and any and all rubbish and debris from the site to the satisfaction of the AEC Construction Inspector
and the Owner. Paved and concreted areas shall be flooded with water to test for proper drainage. Any low or
uneven areas, or areas subject to ponding, shall be corrected to the entire satisfaction of the AEC Construction
Inspector and the Owner. The Contractor shall clean the surface of the concreted and paved Work area, and areas
surrounding the Work which may have become encrusted with soil and debris during construction operations, by
hosing them down with water until clean.
After all cleanup is completed, the Contractor shall repaint any and all lines, parking spaces, and other markings
disturbed during the Work. All painting shall match existing conditions.
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65189
BARCLAYS CALIFORNIA CODE OF REGULATIONS
Titles
(6) Baits cot protected by hood or shield shall be provided with a re-
movablecoverwhicb shall be placed over Shebath during temporary shut
downs and at end of periods of use.
(b) Nitrate Balis. In addition to the requirements of (a):
(1) No salt containing any cyanide or any organic compound shall be
added to a salt bath containing nitrate. Proper warning signs to this effect
shall be posted near ill such baths.
(2) Nitrate baths shall not be operated at a temperature of greater than
1200 degrees F.
(3) Nitrate baths used lo treat aluminum or its alloys shall not be oper-
atedata temperature greater than 1000degrees F. b such baths if the tem-
perature reaches 1000 degrees F, or if the objects being treated and the
bath appear to be beginning an exothermic reaction the operator shall
withdraw (he metal objects from Ihe bath.
(4) Every nitrate bath over lOcubic feet in capacity shall be provided
with an automatic cut-off safety cocao! which will shut off the source
ofheat when the tempera tare teaches the limits set forth in (2) or (3). Th is
control shall be in addition to any regular controls whether Iheyact auto-
matically or manually,
(5) If external heating by gas or oil is used, the combustion chamber
shall be arranged so that the sides of the chamber are bathed in hot gas jes
as uniformlyaspossiblewithoutanyJlamemjpingingdirectlyoQ the con-
tainers and so tbat in case of failure of the coata iner, molten salt will Cow
to a safe place and so that molten salt cannot drip or spauer into the com-
bustion chamber.
(6) The molten salt container shall be emptied at regular intervals and
inspected for deterioration. When inspection shows thai deterioration has
taken place to such ml extent that failure is likely, or that uneven heating
of the salt may occur, the container shall be replaced or repaired
(7) No article shall be allowed to stay in the bottom of the balh. Accu -
mulatioos of sediment or products of partial decomposition shall be re-
moved regularly, as often as is necessary to prevent uneven heating of the
bath. The chemical content of the bath should be checked frequently.
(S) Nitrate shall not be stored in the room with the bath. Storage in a
separate building is recommended,
(95 Buildings in which nitrate baths are located should be of construc-
tion recommended by the Natitxial Board of Fire Underwriters Research
Report, No. 2,1954, for such location. Combustible materials in a room
with a bath shall be kept to a minimum.
(10) Magnesium or magnesium alloy shall not be beat-treated in ni-
trate baths.
(11) When heat is turned off such a bath andbefore it is allowed to cool,
a metal wedge longenou gh to reach from the bottom of the bath to above
ihe surface shall be inserted to prevent explosion when bath is reheated.
Note: Ay-hcritycite'd: Section 142.3, Labor Code. Reference: Section 142.3, La-
bor Code,
Hisroitr
I. Renumbering and amendment of Section 5203 toSeeUon 5188 filed 12-10-87;
operative i-9-38 (Register 87, No. 51).
§ 5189. Process Safely Management of Acutely Hazardous
Materials.
(a) Scope and Purpose.
These regulations contain requirements for preventing or minimizing
the consequences of catastrophic releases of toxic, reactive, flammable
or explosive chemicals. The establishment of process safely manage-
ment regulations are intended to eliminate to a substantia! degree, the
risks to which employees are exposed in petroleum refineries, chemical
plants and other facilities.
(b) Application.
(l)These regulations shall apply to a process which involves a chemi-
cal at or above the specified li reshold quantities listed in Appendix A and
a process which invol ves a flammable liquid or gas as defined in subsec-
tion (c).
EXCEPTION: (I) Flammable liquids stored in atmospheric tanks or
trans ferred which are kept below theirnotnwl boiling point withou (bene-
fit of chilling or refrigeration. (2) Hydrocarbeo fuels used solely for
workplace consumption (e.g. comfort healing propane, gasoline for mo-
tor vehicle reftieling) if such fuels are not part of a process containing
another acutely hazardous chemical covered by section 5189.0) These
regulations do not apply to retail facilities, oil or gas well drilling or serv-
icing operations or normally unoccupied remote facilities.
(2) Explosives manufacturing opera lions shall comply with the provi-
sions of Article 119 and these orders.
(3) The requirements of subsections (d) and (e) shall become effective
within five (5) years according to the following phase-in schedule:
(A) No less than 25 percent shall be completed by August 10,1994;
(B) No less than 50 percent shall be completed by August 10,1995;
(Q No less than 75 percent shall be completed by August 10,1996.
(D) All initial process hazards analyses shall be completed by August
10.1997.
(4) Subsections (f> through (p) shall become effective on January 4,
1994-
(c) Definitions.
Acutely hazardous material. A substance possessing toxic, reactive,
flammable or explosive properties and specific by subsection (b)(1).
Explosive. A substance identified in Title 49, Pan 172 of the Code of
Federal Regulations, the Department of Transportation effective on De-
cember 31,1990.
Facility. The buildings, containers, or equipment wbicb contain a pro-
cess,
Flammable. Liquids or gases as defined in Section 5194(c) onsile and
in cce location in quantities of 10,000 pounds or more.
Hoi Work. Electric or gas welding, cutting, braising or any extreme
heat, (lame, or spark producing procedures or opera!)ens.
Major Accident Any event involving fire, explosion, or release of a
substance covered by this section which results in t fatality or a serious
injitiy (as denned by Labor Code Section 6302) to persons in the work-
place.
Normally unoccupied remote facility. A facility which is operated,
maintained and serviced by employees who visit the unmanned facility
only periodically to check its operation andperformnecessary operating
or maintenance tasks. No employees are permanently stationed to ibis fa-
cility. Facilities meeting lb is definition aienoi contiguous with and must
be geographically remote from all other buildings, processes or persccs.
Process. Any activity conducted by an employer that kivolves an
acutely ba jardous material, flammable substance or explosive including
any use, storage, manufacturing, handling, or oa-sile movement of any
of Ihe preceding substances or combination cf these activities. For pur-
pose s ofth i s de ftnit too an y grou p of v e s sels wh ich are inle rc oonec ted and
separate vessels which are located such that an acuielyhazaidous materi-
al could be in volved is a potential release sh all be cccs idered a single pro-
cess-
Process Safety Management. He application of management- pro-
grams, which arc not limited to engineering guidelines, when dealing
with Ihe ri sks associated wjib handling or working near acutely hazard-
ous materials, flammables, or explosives.
Replacement in Kind, A replacement which satisfies She desip speci-
fication.
(d) Process Safety Mormatioo, The employer shall develop and main-
tain a compilation of written safety information to enable, (he employer
and the employees operating the process to identify and understand the
hazards posed by processes involving acutely-hazardous, flammable and
explosive material before conducting any process hazard analysis re-
quired by this regulation. The employer shall provide for employee par-
tic ipa tioo in ibis process. Copies of this safely information shall be made
accessible and communicated to employees involved in the processes,
and include: 1
(1) Information pertaining to hazards of ihe acutely hazardous and
flammable materials used in the process. This i-ifarmauori shall "consist
of ai least the following:
(A) Toxicity information;
(B) Permissible exposure limits as listed in Section S155;
Paec 810
A-53
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Tide8
General Industry Safety Orders
§5189
(C) Physical data:
(D) Corrosivity data;
(E) Thermal and ehemteal stability da la; ¦
(F) Reactivity data; tad,
(0) Hazardous effect* of incompatible minutes which could foreec-
ably occur.
Note.- Material Safety Data Sheets meeting the requirements of Section 5194(g)
ciaybeuscdio comply with this requirement to the extent they meet die infenna-
Uat provisions.
(2) Information pertaining to fce technology of lie process, Worma-
lion concern ing the technology of Ike proces s shall include at least the fol-
lowing
(A) A block flow diagram or simplified process flow diagram;
(B) Process chemistry;
(O Maximum intended inventory;
(D) Safe upper and lower limits for process variables such as tempera-
tures. pressures, flows, levels tod/or compositions; and,
(E) The consequence* of deviations, including those affecting the
safety sad health of employees.
Note: Far proce sacs f<* whidi data is imavailsbk}tfte information eencGniiflg ihe
technology of Ihe pnxess maybe developed torn a proceisAazanl analysis eon-
ducted in aeccrd&ncE with subsection (e).
(3) Information pertaining to the equipment in the process.
(A) Wormalicu pertaining to the equipment in the process shall in-
clude at least the following;
1. Materials of construction;
2. Piping and instrument diagrams (P&ID's);
3. Electrical classification;
4. Relief system design and design basis;
5. Ventilation system design;
6. Design codes employed including design cccdiUdnsandoperataig
limits*
7. Material and energy balances for processes built after September 1,
1992;
8. Safety systems (such as interlocks, detection and suppression sys-
tems, etc.); and,
9. Electrical supply and distribution systems.
(B) The employer shall document that the equipment complies with
the criteria established in subseclion (d)(3XA) in accordance with recog-
nized and generally accepted good engineering practices.
(Q For existing equipment designed and constructed in accordance
with codes, standards, or practices that are no longer in general use. the
employer shall determine and document that the equipment is designed,
maintained, inspected, tested and operating in a safe manner.
(4) A copy of theprocess safety information and communication shall
be accessible to all employees who perform any duties In or near the pro-
cess.
(e) Process Hazard Analysis.
(1) Hie employer shall perform a hazard analysts appropriate to the
complexity of the process for identifying, evaluating and controlling
hazards involved in the process and dial] determine and documeot the
priority cider for conducting process hazard analyses based on lie e xtent
of process hazards, number of potentially affected employees, age of the
process and process operating histoty, using at least one of the fol lowing
methodologies.
(A) What-If;
(B) Checklist;
(C) What-IMleckJisf;
CD) Hazard and Opembility Study (HA20P);
(E) Failure Mode and Effects Analysis (FMEAJ; or
(Fj Fault-Tree Analysis.
Note The employer may utilize other hazard analysis methods recognized byen-
gincering organizations or governmental agencies. In the absence csf (A; - (F) or
other recognized hazard analysis methods, die employer may utilize a hazard
analysis method developed and certified by a registered professional engineer foe
use by the process hazards analysis team.
(2) The hazard analysis shall address;
(A) The hazards of DC process;
(B) Engineering and administrative controls applicable tothehazards
and their relaticosbips;
(O Consequences of failure of these controls:
(D) Facility Siting:
(E) Human Factors; t
(F) A qualitative evaluation of a range of the possible safety and health
effects of the failure of controls on facility employees, and
(G) The identification of any previews Incident which had a likely po-
tential for catastrophic coisequences m Use workplace.
Nan. Ttie employes may utilize the facility's Risk Management Prevention
Pkn(s) (RMPP) prepared pimuant to Article 2, Cfeapier 6.95 (commencing with
Section 2Sj3l)efDivisiM20efAe Health imtSa&tyCodeto the extent that
is satisfies the requirements of subsections (e)(1) and (2).
(3)(A) The process hazard analysis shall be performed by a team with
expertise in engineering and process operatfcns, and the team shall in-
cludeatleastoneoperatingempleyeewholiasexperieneeandfatowkdge
specific to the prows being evaluated. The team shall also include one
member knowledgeable in the specific process hazard analysis method-
ology being used. The final report containing the results of the hazard
analysis for each process shall be available in the respective work area
for review by any person working in that area.
(B)The employer shall consult with the affected employees and where
appropriate their recognized representatives so the development and
conduct of hazard assessments performed after the effective date of this
sectica. Affected employees and where applicable their representatives
shall be provided access to the records required by this section.
. (4) The employer shall establish a system to promptly address the
team's findings and recommendations; document any actions taken to
implement the team's recommendations; develop a written schedule of
when theseactionsare lobe completed; assure that the recommendations
are resolved in a timely maimer, make Ihem available to operating, main-
teoar.c c and aayothet persons whose work assignments are inthe facility,
and who are affected by the recommendations or actions; and assure (hat
the recommendations are evaluated in a timely manner or implement an
alternative resolu lion which appropriately addresses the degree ofbazard
posed by the scenario.
(5) At least every five (5) years, the process hazard analysis dial] be
updated and revalidated, by a team meeting the requirements in subsec-
tion (e)(3), to assure that the process hazard analysis is consistent with
the current process,
(6) Employers shall retain process hazard analyses and/or updates fa
each process covered by this section, as well as fte documented actions
described in subsecticn (eX4).
(7) Upon request of my worker or any labor union representative of
any worker in the area, the employer shall provide or make available a
copy of the employer's RMPP.
(§) The employer shall conduct the process hazard analysis its soon as
possible butnot later than the dales shown in subsection (b)(3).
(f) Operating Procedures.
(1) The employer shal I develop and Implement written procedures that
provide clear instructions for safely conducting activities involved in
each process consistent with die process safety mfonation aad shall ad-
dress at least (he following.
(A) Steps for each operating phase:
1. Start-up;
2. Normal operation;
3. Temporary operations as the need arises;
4. Emergency operations, including emergency shutdowns, and who
may initiate these procedures;
5. Normal shutdown; and,
6. Surt-up following a tumaraind, or after an emergency shutdown.
(6) Operating limits:
1. Consequences of deviation; '
2. Steps required to correct and/or avoid deviation; and
3. Safety systems and their functions.
(Q Safety and health considerations:
Page 810,1
A-S4
*«*aicr9<.Ne. I: l~*M*
-------
$ 5189
BARCLAYS CALIFORNIA CODE OF REGULATIONS
Title 8
1. Properties of, and hazards presented by, the chemicals used to Ihe
process;
2. Precautions necessary to prevent exposure, Including adsntaisixa.
live controls, engineering controls, and personal protective equipment;
3. CbotresI measures to be taken if physical contact or aiAorne expo-
sure occurs;
4. Safety pracetfcres for'opening process equipment (such as pipe line
breaking);
5. Verification of raw materials ant! control of hazardous chemical in-
ventory levels; and,
6. Any special or unique hazards.
(2) A copy of Ike operating procedures &all be readily accessible to
employees who work in or near the process area or lo any other person
who works in or near the process area,
(3) The operating procedures shall be reviewed as often as necessary
to assure that they reflect sate operating practices, including changes that
result from changes in process chemicals, technology, and equipment;
and changes to facilities.
(4) The employer shall develop and implement safe work practices to
provide for the con trol of hazards during operations such as opening pro-
cess equipment or piping and control over entrance into a facility by
maintenance, contractor, laboratory or other support perscnnrl. These
safe work practices sbsll apply to employees and contractor employees,
(g) Training.
(!) Initial training. Each employee presently involved in operating or
maintaining aprocess, and each employee before waking in a newly as-
signed process, shall be trained ia an overview of the process and in the
operating procedures as specified in subsection (f). The training shall in-
clude empbasis on the specific safety andbealthhazards,procedures, and
safe practices applicable to the employee's job tasks.
(2) Refresher and supplemental training. At least every three years,
and more often if necessary, refresher and supplemental training shall be
provided to each maintenance or operating employee and other workers
necessary to en sure safe operation of Ihe facility. The employer in consul-
tation with employees involved in operation or maintenance ofa process
shall determine tbe appropriate frequency of refresher training.
(3) Training certification. The employer shall assure that each em-
ployee involved in the operation ormamtenanceof a process has received
and successful ly completed training as specified by th is subsection. The
employer, after the initial or refresher training shall prepare a certifica-
tion record which contains the idenli ty of the employee, the date of train-
ing, and the signatures of the persons administering the training.
(4)Testing procedures shallbe established by each employer to ensure
competency in job skill levels and safe and healthy work practices.
(Ji) Contractors.
(1) Tbe employer shall inform contractors performing work on, or
near, a process of Ihe known potential fire, explosion or toxic release haz-
ards related to the contractor "s work and the process, and require that con-
tractors have (rained their employees to alevei adequate lo safely perform
their job. The employer shall also inform contractors of any applicable
safely rules of the facility, and assure that the cextractors have so in-
formed their employees.
(2) The employer shall explain to eonffaclors the provisions of the
emergency action plan required in subsection (b).
(3) Contractors shall as sure that each of their employees have received
training to safely perform-their job and that the ccntraci employees shall
comply with all applicable work practices and safety rules of the facility.
(4) The contractor's (raining program shall be performed ia accor-
dance with the requirements of subsection (g).
(5) Tbe employer when selecting aeon tractor shall obtain and evaluate
information regarding the contract employer's safety program.
(6) The employer shall periodically evaluate the performance of con-
tract employers ia fulfilling (heir obligations as specific in subsection
(h)(3) of this section.
(7) The employer shall obtain and make available upon request a copy
of the contract employer's injury and illness teg related to the contrac-
tor's work in the process areas.
Paw
(i) Pre-stait Up Safety Review,
(1) Tbe employer shall perform a pre-sttrt up safety review for new
facilities and for modified facilities for which the modification necessi-
tates a change in the process safely information.
• (2) The pr»-stait up safety review shall confirm (hat prior to the mtro-'
duciioo of acutely hazardous, flammable tad explosive materials to a
process:
(A) Construction aad'or equipment are in accordance with desijp
specifications;
(8) Safety, operating, maintenance, and emergency procedures are in
place and are adequate,
(Q For new facilities, a process hazard analysis has been performed
and recommendations have been resolved or implemented before start-
up; and modified facilities meet Ihe requirements contained in subsection
(f); and,
(D) Training of each operating employee and maintenance worker has
been completed.
(3) The Pre-Start Up Safety Review shall involve employees with ex-
pertise in process operations and engineering. Tbe employees will be se-
lected based upon their experience and understanding of the proce sj sys-
tems being evaluated,
(j) Mechanical Integrity.
(1) Written procedures.
(A) The employer shall establish and implement written procedures to
maintain the ongoing integrity of process equipment and appurtenances,
These procedjres shall include a method:
1. for allowing employees to identify and report potentially faulty or
unsafe equipment; and
2. to record their observations and suggestions in writing.
(B) The employer shall respond regarding the disposition of the em-
ployee' s concerns contained in the repon(s) in a timely manner.
(C) The employer shall provide employees and their representatives
access to the information required in subsection (jXl).
(2) Inspection and testing.
(A) Inspections and tests shall be performed an process equipment.
(B) Inspection and testing procedures shall follow recogn ized and gen-
erally accepted good engineering practices.
(C) The frequency of inspections and tests shall be consistent wiih
applicable manufacturer's recommendations and good engineering prac-
tices and more frequently if determined necessary as dictated by operat-
ing history.
(D) The employer shall have a certification record that each inspection
and testhas beeiiperformed in accordance with (hissubsecrico. Tbecerti-
fication shall identify the date of the inspection; the name of the person
who performed the inspection and test; and the serial number or other
identifier of tbe equipment.
(3) Equipment deficiencies. The employer shall correct deficiencies
in equipment which are outside acceptable limits defined by the process
safety' information ia subsection (d) before further use, or in a safe and
timely manner provided mean s are taken to assure safe operation.
(4) Quality assurance,
(A) The employer shall assure that in the construction or new plants
and equipment modified, repaired, or fabricated equipment is suitable for
the process aplieatiou for which (hey will be used
(B) Appropriate checks and inspections shall be performed as neces-
sary to assure that equipment is installed properly and is consistent wiih
design specifications and manufacturer's instructions.
(C) The employer shall assure that maintenance materials, spare pans
and equipment, meet design specifications and applicable codes.
(k) Hot Work Permit.
(1)Theecplojer shall develop and implement a written procedure for
the issuance of "hot work" permits,
(2) The permit shall certify th at the applicable portions of the fire pre-
vention and protection requirements contained in Sections 4848 and
6777 have been implemented prior to beginning the hot work operations;
>.2 CM V. « I -7-4*
A-55
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General Industry Safety Orders
$5189
indicate the to en-
ter into confidentiality agreements prohibiting them from disclosing the informa-
tion asset forth in Section 5194.
NOTE. Authority cited: Section 142J, Labor Code. Reference: Sections 142J and
7856, Labor Code.
History
1. New section Wed 7-10-92; operative &-J0-92 (Register 92, No. 28).
2. Aroendme nt of section and new Appendix filed 1 -4-54, operative I 4 94 pur-
ru&iK io Government Code section 11346.2(d) (Register 94, No. I).
Appendix A to Section 5189—List of Acutely Hazardous
Chemicals, Toxics and Reactives (Mandatory)
This Appendix contains a listing of substances wb ich present a poten-
tial for a catastrophic event atorabove the threshold quantity CTQ)
Paw Kin.*
A-56
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§5189
BARCLAYS CALIFQ RNIA CODE OF REGULATIONS
Titles
CHEMICAL name
Acetaldehydfi
Acrolein (2-Propeoal)
Acrylyl Qloride
AEylChloride
Allylamiie
Alkylahimioums
Ammmb AfifeydrOUJ .
Ammonia sclusions (> 44%
ammonia by weight
Ammonium Percbloraxe
Ammonia m Permanganate
Arsiue (also called Arsenk
Hydride)
BssfObloromelbyl) Edbet
Boron THchloride
Borcm Trifluoride
Bromine .... -
. Bromine Chloride
Bromine Pentafluoride
" Bromine Trtfluoride
3-Bromapropyne (also called
Ptopaigyl Bromide)
Butyl Hydroperoxide (Tertiary) ....
Butyl Perbenzoala (Tertiary)
CaAonyl Chloritfc (see Phosgene) .
Caibonyl Fluoride Cellulose Nitrate
(concentration > ! 2.6% nitrogen).
Glorine -•
Chlorine Dioxide
Chlorine Pentraflyaide
Chlorine Trifluoride
Oslorodiethylalumimim (also called
rswlhylatimiiniim Chloride) . .. . .
l-Chloro-2,4-Dinittobenzeae
Qjlororaelbyl Methyl Ether.......
Chloroplcrir,
Cbloropieric and Methyl Bromide
mixture .. .¦
Qloropicrin and Methyl Chloride
mixture
Cumene Hydroperoxide
Cyanogen '
Cyanogen Chloride ,.
Cyaruric Fluoride
Diacetyl Peroxide (Concentration
> 70%)
Diazomethane '
DibenzoyI Peroxide
Diborane !
Dibulyl Peroxide (Tertiary)
Diet toro Acetylene
Dichlorosilane ¦
Diethylzinc
CAS*
75-07-0
107-02-8
814-68-6
1 60%)
Ethyl Nitrite
Elhylamine
Ethylene Fluorehydrin
Ethylene Oxide
Ethytaeimine
Fluorine
Formaldehyde (Formalin)
Furan
Hexafluoroacelone ..
Hydrochloric Arid, Anhydrous
Hydrofluoric Acid, Anhydrous
Hydrogen Bromide
Hydrogen Chloride
Hydrogen Cyanide, Anhydrous .....
Hydrogen Fluoride
Hydrogen Peroxide (52% by wei^il
or greater
Hydrogen Selemde
Hydrogen Sulfide
Hydroxylamine
Iron. Pentacarbonyl
Isopropykmine
Keteae
Melhaciylaldehyde
Methaciyloyl Chloride
Meihacryloyloxyelhyl Isocyanate ...
Methyl Acrylooitrile
Methylauiine, Anhydrous
Methyl Bromide
Methyl Chloride
Methyl Qlorofonnate
Methyl Ethyl Ketone Peroxide
(concentration > 60%)
Methyl Fluoroacetate
Methyl Fluoiosulfate
Methyl Hydrazine
Methyl Iodide
Methyl bocyanate
Methyl Mercaptan
Methyl Vinyl Ketone
Methyltrkhlorosilaue
Nickel Caibocly (Nicfcel
Tetracarbonyl)
CAS*
105-64-6
105-74-8
75-78-5
57-14-7
124—40-3
97-02-9
1338-23-4
109-95-5
75-04-7
371-62-0
75-21—8
IS 1-56-4
7782-41-4
50-00-0
110-00-9
6S4-16-2
7647-01-0
7664-39-3
10035-10-6
7647-01-0
74-90-8
7664-39-3
7722-84-1
7783-07-5
7783-06-4
7803-49,-8
13463-40-6
75-31-0
463-51—4
78-85-3
920-46-7
30674-80-7
126-98-7
74-89-5
74-83-9
74-87-3
79-22-1
1338-23-4
453-18-9
421-20-5
60-34-4
74-88-4
624-83-9
74-93-1
79-84—4
75-79-6
13463-39-3
Pano Kind
A-57
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Title?
General Industry Safety Orders
§5190
CHEMICAL name
CAS*
TQ**
Nitric Acid {94.5% by weight or
greater) •
7697-37-2
500
Nitric Orida
10102-43-9
250
Nitrcoailine (para Nitroaailiae
100-01-6
5000
Nitromethane
75-52-5
2500
Nitrogen Dioxide
10102-44-0
250
Nitrogen Oxides (NO; NOj; N204;
N203)
10102-44-0
250
Nitrogen Tetroxide (also called Nitro-
gen Peroxide)
10544-72-6
250
Nitrogen Trilluoride
7783-54-2
5000
Nitrogen Trioxide
10544-73-7
250
Oleum (65% to 80% by weight; also
8014-94-7
called Fuming Sulfuric Acid)
1000
Osmium Tetroxide
20616-12-0
too
Oxygen Di fluoride (Fluorine Monox-
7783-41-7
100
ide)
Oione
10O2S—15—6
10S
Peataboxaac
19624-22-7
J 00
Feraceuc Acid (ctmcenlralion > 60%
Acetic Acid; also called
Peroxyacetle Acid)
79-21-0
1000
Perchloric Acid (concentration > 60%
by weight)
7601-90-3
5000
Percblowraetbyl Mercapwa
594-42-3
150
Perchloryl Fluoride
7616-94-6
5000
Peroxyacesic Acid (concentration >
60% Acetic Acid; also called
Peracetic Acid)
79-21-0
1000
Phosgene (also called Caxbonyl
Chloride)
7S-44-5
100
Phospbint (Hydrogen Phosphide)
7803-51-2
100
Phosphorus Oxychloride (also called
Phosphoryl Chloride)
10025-87-3
1000
Phosphorus Trichloride
7719-12-2
1000
Phosphoryl Chloride (also called
Phosphorus Oxychloride)
10025-87-3
1000
Prcpargyl Bromide
106-96-7
100
Propyl Nitrate
627-3-4
2500
Sarin
107—44-8
100
Selenium Hexafluoride
7783-79-1
1000
Stibine (Anlimeoy Hydride)
7803-52-3
500
Sulfer Dioxide (liquid)
7446-09-5
1Q0Q
Sutfer Psnlafluoride
5714-22-7
250
Sulfer Tetrafluoride
7783-60-0
250
Sulfur Trioxide (also called Sulfuric
Anhydride)
7446-11-9
1000
Sulfuric Anhydride (also caDed Sulfer
Trioxide)
7446-11-9
1000
Tellurium Hexafluoride
7783-80-4
250
Tetrafluoroethylene
116-14-3
5000
Tetrafluorohydraziite
10036-47-2
5000
Teuamethyl Lead
75-74-1
1000
Tbionyl Chloride
7719-09-7
250
CHEMICAL name
CAS*
TQ**
Triehloro (chloromethyl) Silane
1558-25-4
100
Tricbloro (dicbloiophenyl) Silane ....
27137-85-5
2500
Trichlorosikne
10025-78-2
SOQO
TrifluorochloroethykDe
79-38-9
10000
Trimethyoxysihne
2487-90-3
1500
•Chemical Abstract Service Number,
"Threshold Quantity in Pounds (Almost necessary to be
covered by this standard).
Ntrtt- Autficritycsitd. Section 142 J, Labor Code. Reference: Section! 1423
and 765S, Labor Code.
{ St90. Cotton Dust
(a] Scope and Application.
(1) This section applies to the control of employee exposure to cotton
dust in all wortepkees where employees engage in:
(A) Y uti manufacturing;
(B) Slashing and weaving operations;
(C) Work ia waste houses for textile operations;
(D) Preparation of washed cotton (tot opening until the cotton is thor-
oughly wetted; i
(E) Yam manufacturing and slashing and weaving operations exclu-
sively using washed coSloc (as defined by Sec lion 5190(e) only to the ex-
ten! specified by Section 5190(n).
(F) Cottonseed processing or waste processing operations only w the
ex tent Section 5 190(b) Medical Surveillance, (V)(2>-(4) Recordkeeping
Medical Records, and Appendices B. C, and D apply.
(2) This section does not apply to;
(A) The harvesting of cotton;
(B) The ginning of cotton;
(Q Ship end boatbuilding or ship repair and breaking operations, as
defined by 8 Cal, Admin. Code 8347, and longshoring;
Note: Langshormg is defined as the loading, unloading, moving, or handling of
cargo, ship i stores. gear, etc. into, in, cr., of Oct of vessel on the navigable
waters of the Uniled Slates.
(D) The handling or processing of woven or knitted material.
(E) Knitting, classing or warehousing operations eacr.pt that employ-,
ers with these operations, if requested by KIOSH, shall grant NIOSK ac-
cess ID their employees and workplaces for exposure monitoring and
medical examinations for purposes of a health study to be performed by
NIOSH on a sampling basis;
(F) The ccoswjciion industry.
(b) Definitions.
Blow down. The general cleaning of a room or a part of a room by the
use of compressed air.
Blow off. The use of compressed air for cleaning of short duration and
usually for a specific machine or any portion of a machine.
Chief. The Chief of lie Division of Occupational Safely and Health,
or designee.
Gotten Dust. Dust present in the air during lie handling or processing
of cotton, which may contata • mixture of many substances including
ground-up plant matter and other contaminants which may have accu-
mulated with the eotloo during the growing, harvesting, and subsequent
processing or storage periods. Any dust present during the handling and
prtxessingof cotton through the weaving or knitting of fabrics, and dust
present in other operations or manufacturing processes using raw or
waste cotton fibers or cotton fiber byproduc is from textile mills are con-
sidered cotton dust within this def nition. Lubricatingoil mist associated
with weaving operations is not considered cotton dust.
A-58
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APPENDIX B
EQUIPMENT DRAWINGS
• Hydropyrolysis Reactor (HPR) R-101 B-2
• Hot Gas Filter Vessel F-104 B-21
• Gas Scrubber Vessel S-101 B-49
• Zinc Oxide Desulfurization Vessel F-205 B-68
• Biomass Feed System LH-801, T-805, SF-806 . B-91
B-l
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8570 M 108 CYCLONE SCRUBBER SPOOL WELDMENT
L/M 8570M109 OVERFLOW SPOOL WELDMENT {Ust of Matoriah)
6570 M109 OVERFLOW SPOOL WElflMEMT
L/M 8570M110 SCREW CONVEYOR SPOOL WODMENT {Ust of Malarial*)
8570 M110 SCREW CONVEYOR SPOOL WELDMENT
L/M 8S70M1115 OAS WLET SPOOL WELDMENT (LW of Materials)
8570 M111 OAS INLET SPOOL WELDMENT
LIU 6570Ml 12 CYCLONE SCRUBBER WELDMENT {Ust o# Matertab)
BS70 M 112 CYCLONE SCRUBBER WEL0MENT
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A.E.C. PROJECT No. m?4
Proparoi by
ACUREX ENVIRONMENTAL
CORPORATION .
MOUNTAIN VIEW, CALIFORNIA
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0 1.06 THRU AND C'BORE 0 1.330 x .62 DEEP
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24' CUSS 300 C.S. BLIND FLANGE
R 3.55
0 3.06 THRU AND C'BORE 0 3.535 x 1.00 DEEP
VESSEL R-101 TOP FLANGE
SCALE; W-V-O'
-------
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0\
14" CLASS 300 C,S. S.O. FLANGE
14* SCH. 40 C.S. PIPE
T.B.D
16 1,0.
26 I D.
24" CLASS 300 C.S. S.O. FLANGE ,
TYPICAL 2 PLACES
7 CLR.
ANNULAR SPACE FOR
STEAM JACKETING
T.B.D.
24" SCH. 40 C.S. PIPE
1/2" C.S. PLATE ROLLED AS REQ'D. FOR STEAM JACKET
1/2" FNPT NOM, OUTLET REDUCING 3000 LB.
C.S. THREDOLET TYPICAL 2 PLACES
VESSEL R-101 - PRODUCT OUTLET PORT SPOOL PIECE (?)
EC ALE: W-r-a1 '
-------
24* CLASS 300 C.S. S.O. FLANGE TYPICAL 2 PLACES
W
•lo
T.B.D.
/- 1/2* FNPT NOM, OUTLET REDUCING
^ 3000 LB. C.S. THREDOLET
TYPICAL 5 PLACES
1/2* C.S. PLATE ROLLED AS
REQ'D. FOR STEAM JACKET
T.B.D
24' SCH. 40 C.S. PIPE
T.B.D
T.B.D.
T.B.D
26 I.D. STEAM JACKET
VESSEL R-101 - CYCLONE SPOOL PIECE (5)
SCALE: JM-.r-O*
-------
24* CLASS 300 C.S. S.O.
FLANGE TYPICAL 2 PLACES
80¥4,
T.B.D
T.B.D.
T.B.D
T.B.D
30 0
2* FNPT NOM. 3000 LB. C.S.
THREADED COUPLING
TRIMMED AS REQ'D.
1/2" FNPT NOM. OUTLET REDUCING
3000 LB. C.S. THREDOLET
TYPICAL 6 PUCES
26 I.D. STEAM JACKET
24* SCH. 40 C.S. PIPE
&
T.B.D.
15V16
16" SCH. 40 C.S. PIPE
1/2" C.S. PLATE ROLLED AS REQ'D FOR STEAM JACKET
16' CLASS 300 C.S.
S.O. FLANGE
T.B.D.
18 I.D. STEAM JACKET
71/4 CLR.
VESSEL R-101 - FEEDSTOCK OVERFLOW PORT SPOOL PIECE (5)
SCALE: 1/2'-I'-G" W
-------
I
24" CLASS 300 C.S.
S.O. FLANGE
TYPICAL 2 PLACES
1/2* C.S. PLATE ROLLED AS
REQ'D. FOR STEAM JACKET
16" SCH. 40 C.S. PIPE
60 0
,Kpci
7 CLR.
26 I.D
18 I.D
T.B.D.
T.B.D.
2' FNPT NOM. 3000 L" C.S.
THREADED COUPLING .flIMMED
AS REQ'D.
24* SCH. 40 C.S. PIPE
1/2" FNPT NOM. OUTLET REDUCING
3000 LB. C.S. THREDOLET
TYPICAL 4 PLACES
ANNULAR SPACE FOR
STEAM JACKETING
16" CUSS 300 C.S. S.O. FLANGE
VESSEL R-101 - SCREW CONVEYOR PORT SPOOL PIECE (4)
scale: w-r-o- Vi'
-------
14* CLASS 300 C.S. S.O. FLANGE
24" CLASS 300 C.S. S.O. FLANGE
14" SCH. 40 C.S. PIPE
1/2" C.S, PLATE: ROLLED AS
RECTO FOR STEAM JACKET
T.B.D,
•«* 16w »•-
3 CLm
16 l.D.
26 l.D
7 CLR
16" SCH. 40 C.S. PIPE
T.B.D
24" SCH. 40 C.S, PIPE
ANNULAR SPACE
FOR STEAM
JACKETING
24" SCH, 40 C.S. PIPE CAP
T.B.D
16* CLASS 300
C.S. S.O. FLANGE
1/2* FNPT NOM. OUTLET REDUCING 3000 LB.
C.S. THREDOLET TYPICAL OF 4
VESSEL R-101 - MIXED GASES INLET PORT & ASH OUTLET PORT SPOOL PIECE ©
est&a c. tin __ «i ai
SCALE: 3/4*«1*«0'
-------
B-ll
-------
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61
52
e
x
-------
-------
61
B-14
-------
B-15
-------
B-16
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-------
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I
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OO
MINIMUM WALL THICKNESS CALCULATIONS FOR VESSEL R-1Q1
24' O.D. CYLINDRICAL WALL
Maximum Werfdng Pr«$ur* P - 550 pel
Outslda Radius R- 12 H
Material Stress Value S - IS,000 psl (SA-tOA Oraifc 6)
Joint Effldency E - 0,85
Corrosion Allowance C. A. - 0.125 ft.
WsflThlCJawM I- ((P" R) / ((S " E) 4 (0.4 " P))) ~ C. A.
!¦ 0.634 In.
2«S* 0,D. ELLIPSOIDAL HEAD
Maximum Wortdflg Pfftssur* P • £50 pot
Oiftslds Diameter D - 24 la
MatartalSfresiValue S« 16,300 psi {SA-S1SQr»da
Joint Efficiency E * 0.65
Corrosion Allowance C. A.* 0,135 In,
Wan Thickness i« ((P*D)/((2'S*E) + (1.8#PJfl*C.A.
U 0.565 In.
Maximum Working Pressur# P * 650 psi
CHiftld#Diameter D- 24 frv
Malaria! Stress Vafua S- 17,SCO ps! (SA-615 Grade 7C)
Joint Efficiency E» 0.65
CorroslofiAltewanee C. A.« 0.125 H
WaUTWcfcmss I- ((P*0}/{(2,3#E)4(1.fl*P)fl4C.A.
i ¦ 0.554 Irv
Page I o?2
t
-------
w
MINIMUM WALL THICKNESS CALCULATIONS FOR VESSEL R ¦ 101
14" NOMINAL PIPE CYLINDRICAL WALL
Maximum WsMng Pressure P - 550 psl
Outside Radius R ¦ 7.000 In.
Malarial Slrass Value Sa 15,000 pal (SA-108 Qftd* B)
Joint Efficiency E- 0JS
Cocroston AnowaiMfl C.A.- 0,125 in.
WaflTWCtaWM I. |(P-R)/((S*E)»(0.«" !»)))~ C. A.
I» 0422 In.
1 r NOMINAL PIPE CYLINDRICAL WALL
Maximum WarfcfrgPrassur® p. 650 pal
CMsldsRaUlue R- 8.000 In.
Malarial stress Value 8 - 15,000 psl (SA-106 Grade B)
Joint Efficiency E • 0.85
Corrosion AKowancd C. A. • 0,125 h.
WallTWcknesi I. ((P • R) > ((6 • E) ~ (04 • p ))] ~ C. A-
la 0.484 In.
28" 1.0. STEAM JACKET CYLINDRICAL WALL
Maximum WortdngPressure P» 350 pel
Outside Radius R> 13.500 b.
, Material Stress Value Sa 1S.000 pel (SA-tOSOiadeB)
Joint Efficiency E. 0.85
Corrosion AHowance C, A.« 0*125 In.
WalTNdtneaa !- ((P ' R)/« S • e I+ (0 4 ¦ P))) *C. A.
t. 0.492 in.
Page 2 of 5
-------
w
to
o
INTERNALLY INSULATED VESSEL fM®1
DESMN PEftAttETEftf ^
OPERATING PRESSURE •
MAXIMUM WORHNO PRESSURE «
0ESB* PRESSURE®
HYDROSTATIC TEAT PRESSURE-
WfTEftNAL OPERATING TEMPEfWTURE-
' " VESSEL SKIN TEMPERATURE,
OPERATING (NO JACKET STEAM )•
VESSEL SKIN TEMPERATURE,
MAXIMUM (NO JACKET STEAM)*
VESSEL SKIN TEMPERATURE,
OESKJN (WITH JACKET STEAM) -
OASES, OPERATING FLOW
METHANE (NATURAL OAS. CM4|«
carbon monoxtde (coj-
CAR80N moxm »
CARBON DIOWDE (C02J»
HYPnOOEN (H2|«
STEAM (H20)-
ATR-
WTBOOEH fNf )¦
FEEDSTOCK OFFOAB-
TOTAL-
r o.m. costing
ma9 psKi
ISfcOO P8KI
trs.oo pmi
MQQJ* PSIQ
1471 b \m f
230 f
X7S T
480 f
•jo sen*
ijm seru
tj» ten*
*\A6 tent
263 sera
o.oo sera
}« SCFM
S.I7 9CfU
T0BO SCTM
T.40 BCFIi
S.M SCFM
TJt scm
4140 sen*
in KFW
IDS SCfM
48 MI SCfM
C,l? SCfM
11BJU SCFM
-------
DRAWING No.
L/M 8506 M 300
8506 M 309
L/M 8506 M 301
8506 M 301
L/M 8506 M 302
8506 M 302
L/M 8506 M 303
8506 M 303
L/M 8506 M 304
8506 M 304
L/M 85Q6 M 305
8506 M 30S
L/M 8S06 M 306
8506 M 306
L/M 8506 M 307
8506 M 307
8506 M 308
8506 M 309
8506M310
8506 M 311
8506 M 312
8506 M 313
8506 M 314
8506 M 31S
8506 M 316
8506M317
8506 M 318
IWDEK
TITLE
ASSEMBLY (Uat of Materials)
ASSEMBLY
TOP REFRACTORY (Llsl Ol Materials)
TOP REFRACTORY
MIDSECTION REFRACTORY (Uat of Materials)
MIDSECTION REFRACTORY
BOTTOM REFRACTORY (Uit of Materials)
BOTTOM REFRACTORY
TOP WELDMENT (List of Materials)
TOP WELDMENT
MIDSECTION WELDMENT (Uit of Materials)
MIDSECTION WELDMENT
BOTTOM WELDMENT (List of Materials)
BOTTOM WELDMENT
CANDLE FLANGE WELDMENT (Ust of Materials)
CANDLE FLANGE WELDMENT
24- WAFER CANDLE FLANGE
CANDLE FLANGE OUTER SPRING
CANDLE FLANGE INNER SPRING
CANDLE INNER FLANGE PIECE
CANDLE SUPPORT PIPE
CANDLE MOUNTING PLATE
CANDLE ADAPTER PLATE
CANDLE BELL PLATE
CANDLE (REFERENCE ONLY)
ELECTRIC HEATER H-102 (REF.)
PULSE TUBE
^v« u
0
#
I
H Y NO L
FILTER ¥(
F - D©4
A.E.C. PROJECT No. ®S0®
Prepared by
Acuriex environmehtal
mRmmmm
MOUNTAIN VIEW, CALIFORNIA
-------
Acurtx Environmental Corporation
CRT"
HYDROCARB HPR
inu
FILTER VESSEL F-104
ASSEMBLY
AIYItiSWl"
TSflSfflf
M MR *iHI
L/M8506M300
LIST OF MATERIALS
' "Wlff ""
1 of I
3a
Yl£fERLNd<"fiAXWM&r
RELEASED FOR REVIEW
RELEASED FOR REVIEW
8508*000 FLIER VESSEL F»l« AS5CMBL*
PART NUMBER
DESCRIPTION
FUER VESSEL *»W TOP REFRACTOR*
hltbr vessel m« nosectioN refractory
PLtER VESSEL F-I&t dOTTDM REFRACTORY
FlTER VESSa MM CANDLE FLANGE WEUMEXT
FM.TER VESS& IMM CANXE ADAPTER PlATt
FMCT VESSEL F*fM CAMQtE BOX PUTS
FILTER VESSBL F-K* GANOLE {REFEREMPE ONLY)
FLTER VESSEL F>1M EUCTOiC ICATCR H-1Q3 |HEF.)
FV.m VESSEL F-!0< PULSE TU6£
PA*KE« 8-SFH4BZ-M
THERMOCOUPlfi CONNECTO*. \/T TUBE OJ>. a l*T MWT MCGNEL AU.0* «W | I
PARKER 4-6FBZ-SS
WALE CONNECTOR. Ml' WOE OD. I IflT fcffPT
TWE 318 STANLEY STEEL
THERMOCOUPLE CONNECTOR.
W TUBE 0.0, * \fT MNPT
PAJ90ER 441 FH4aZ-aS
TYPE 31# STAINLESS STEEL
H£AW HEX HUT. WASHER FACED,
CARSON STECL 1 m 0
STUD BOLT. f-?«*-0UN.2A i 1MT LCNQ
CAJttON trrfEL I 24
STUD BOLT. l-7/H-.flUNC-lA X U* U3N9
CARSON STEEL I 2«
HEX NUT, FVIISNED, W-WUNC
ROLLED ALLOYB MSS0 | 1J
PUT WAStCft 1M* HOMHAL
rolled Auort tune I *.2
STUD BOLT. |/4*»2QUNC I MM* LONQ
ROLLED ALLOYS RASM
ftJEXfTALLtt No. C04X
(** SUPER»FLEXfTE)
GASKET, £«*-000t FWSED FACE tUflOCS
INSULATION PAPER, 1M* THC* ( SHAPE M REOUWEDI
CCNAX TG-14-M-L
ELECTRICAL CONfCCTOR. WSUlATfB HKJH PRESSURE OUND
-------
OV^ JCr
M4/
rir
Acurex Environmental Corporation
W4.ML 1* OA tut
«r r
• IMt
L/M8506M301
HYDROCARB HPR
tw
*m
mmm
FILTER VESSEL F -104
TOP REFRACTORY
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fg ImMiM.1 n — - —
1 of 1
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on
1MB DM
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immiB
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MQHCDO
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8506
1?
PART NUMBER
DESCRIPTION
on m* mm. -
•M
m
m
m
1
FLTER VESSH. P • 104 TOP IMOJPMEIfT
1
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9
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Cd
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-P*
21) 6 Ft (SHOWNI 9 22.5*. 8?J*. 1125-, 157.5*, S02.S*, 247.6*. 2925*. AND 3J7.6- ELECTBICAL PORTS
I 1 PL (NOT 6HQWf0 O 0,0* THERMOCOUPLE POUT
j O 0,0° THERMOCOUPLE PORT
24 PL
41 PL
24 PL
13149 PL
W///MM/MM
inj HH"
Sjj^
NOTE;
9) 3 PL
12 PL
12 PL
file PL
FOh THE UST OF WATERiALS, SEE
L/MBS06M30a
INSTRUMENTATION PORT
PROCESS INLET
vm-
CMK
TATE Oft-25-63
Aeurex EnvironmtnUil Corporation
(¦neuter
HYDROCARB HPR
RELEASED FOR REVIEW
HELEASEO FOH REVIEW
RELEASED FOH REVIEW
PHcxff ci m, asoe-400
FILTER VESSEL F-104
ASSEMBLY
SHEET
1 or i
RlTOiSRT"
urn
REFERENCE DRAWINGS
8506M300
REV
3a
-------
CO
N>
Ul
NOTE:
FOR THE LIST OF MATERIALS, SEE
L/M 8506M301.
EFRACTORY SHALL BE FLUSH WTO THE
GASKET SURFACE OF THE FLANGES
0 1/4*
32-7/16* REF
D, J. TATE 08-25-93
Acurex Environmental Corporation
rm&di
HYDROCARB HPR
FILTER VESSEL F-104
TOP REFRACTORY
8508-*OQ
PftOJECT NO.
RELEASED FOR REVIEW
1/10
wsrwr
MKBmran
omrm
smr
1 of 1
8506M301
RfctflSlONS
REFERENCE DRAWINGS
-------
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2' HEF
0%'{9 PL) AT THREDOLETS
SEE DWQ. 8506M305
Zjg® S fc c
n O Q
0 W AT THREDOLET
SEE DWQ. B506M305
REFRACTORY SHALL BE FLUSH WITH THE
GASKET SURFACE OF IKE FLANGES
SHALL BE FLUSH WITH THE
CE OF THE FLANGES
NOTE:
FOR THE LIST OF MATERIALS, SEE
L i M 850BM302
"B®" D.J, TATS 108*25-93
W
Acurei Environmental Corporation
KYDHOCARB HPB
PFWJ6CT NO. 6503*400
released for review
09-^53
6CAUE 1/10
FILTER VESSEL F-104
MIDSECTION REFRACTORY
mm£~
1 of 1
BkEf
"REVISIONS
BEFERENCE 0RAWINQS
1 : ar
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8506M302
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1
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63
I
to
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30* REF
REFRACTORY SHALL BE FLUSH WITH
THE GASKET SRUFACE OF THE FLANGE
REFRACTORY SHALL BE FLUSH WITH
THE GASKET SRUFACE OF THE FLAN3E
NOTE:
FOR THE tIST OF MATERIALS, SEE
L/ M 65D6M303.
"™ O J. TATE [0^23-93
Acurex Environmtntal Corporation
HYDROCARB HPR
RELEASED FOR REVIEW
DJT
08-83-93
PROJECT MO. 6506 - 400
SCALE
tuawwrergr
FILTER VESSEL F-104
BOTTOM REFRACTORY
"""BMkei"""
1 of 1
HEVISiOFJr'
REFERENCE DRAWINGS
8506M303
REV
1
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MAWfflU
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L/M8506M303
«MM5
HYDROCARQ HPfl
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PART NUMBER
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-
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NOTE:
TOH THE LIST OF MATERIALS, SEE
L/M 8506M304
JJ'/ielB
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cp-Vtv-©^
< 32-7/16 REF
xh/»6|a|
NOTES:
1, BOLT HOLES SHALL STRADDLE
CEMTERLINES.
p,x Tate ja»-as^a
Acurex Enrin>nmejji6t Corporation
RatASFD FOR REVIEW
"TiEVreiQiFIS
>mi
REFERENCE DRAWINGS
pflCMECT NO. 8508 - 400
KXJ
PHCufcCT"'
HYDHOCARB HPR
FILTER VESSEL F-104
TOP WiLDMENT
8506M304
sheet
I of 1
rev
1
-------
Acurex Environmental Corporation
L/M8506M3Q4
HYOROCARB HPH
Da •
W '
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FILTER VESSEL F-104
TOP WELOMENT
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JJi/ieW
12 -M
1/4 MIN
NOTES
1. BOLT h4lES SHALL STRADDLE CENTEfiUNES
<^o
NOTEi
FOR THE LIST OF MATERIALS. SEE
L/M85Q6M305
O. J. TATE Ofr-25-83
Acurex Environmental Corporation
KYDROCAHB HPR
FILTER VESSEL F-104
MIDSECTION WELDMENT
PROJECT NO. 8506-400
RELEASED FOR REVIEW
09-23-03
1/10
BTOTO
SHEET
1 of i
8506M305
RevisioFfs
REFERENCE DRAWINGS
mssra
-------
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FOR THE LIST OF MATERIALS, SEE
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D. A TATE 08-25-®
Acarex Envinnmtntal Corporation
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hydrocarb Hpn
FILTER VESSEL F-104
BOTTOM WELDMENT
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Acurex Environmental Corporation
HWJMlll1 lutiui
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O.J. TAIL OB-25-93
Aeurex Environmental Corporation
hydrocahb hpb
FILTER VESSEL F-104
CANDLE FLANGE WELDMENT
8506-400
PBOJECT MO
RELEASED FOR REVIEW
8506M307
1 of 1
REVISIONS
REFERENCE DRAWINGS
-------
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FINISHES HAVING fROM 24 TO 40 GROOVES PER INCH SERRATIONS
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Aeurex Environmental Corporation
HYDROCABB HPR
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8506M308
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"REVISIONS
REFERENCE DRAWINGS
B
o506M310
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HYDROCARB HPR
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1/2
8506M312
REVISIONS
REFERENCE DRAWINGS
-------
6 x 60"0'
0 4,055
.250
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1/2
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REFERENCE DRAWINGS
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REtfASEO FOft REVIEW
1/2
SUE IPWU.MO
REFERENCE DRAWINGS
-------
,002
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1/2
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REFERENCE DRAWINGS
J
-------
1.500 METERS (59.055 INCHES)
m-
60 MILLIMETERS (2.362 INCHES)
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REFERENCE DRAWINGS
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FOUR QUARTER SECTIONS
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RELEASED FOR REVIEW
REVISIONS
FILTER VESSa M04 ASSEMBLY
REFERENCE DRAWINGS
c™ D.j, TATE 06-25-93
ZST"
project no. 6506**00
BCALE
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Acurex Environmtnlal Corporation
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INOEJC
DRAWING No.
TITLE
UM 8574 M 100
ASSEMBLY (Ust of Materials)
8574 M 100
ASSEMBLY
UM 6574 M 101
TOP WELDMENT (List of Materials!
8S74 M tOt
TOP WELDMENT
UM 8574 M102
MIDSECTION WELDMENT (U«t ol Materials)
8574 M 102
MIDSECTION WELDMENT
UM 6S74 M103
BOTTOM WELDMENT (List of Materials)
8574 M 103
BOTTOM WELDMENT
UM 8574 M 104
DIFFUSER TUBE ASSEMBLY (List of Materials)
8574 M 104
DIFFUSER TUBE ASSEMBLY
UM 8574 M 105
TOP OVERFLOW PIPE SPOOL (Ual ol Materials)
8574 M 105
TOP OVERFLOW PIPE SPOOL
UM 8574 M 106
BOTTOM OVERFLOW PIPE SPOOL (List of
Materials)
8574 M tOS
BOTTOM OVERFLOW PIPE SPOOL
UM 8574 M 107
GAS INLET PIPE SPOOL (List of Materials)
8574 M 107
GAS INLET PIPE SPOOL
UM 6574 M 108
DIFFUSER TUBE WELDMENT (List ol Materials)
8574 M 108
DIFFUSER TUBE WELDMENT
8574 M 109
DEM1STER PAD SUPPORT RING
8574M110
STILLING WELL BAFFLES
8574M111
SCREEN
8574M112
SCREEN CLAMP RING
8574M113
DIFFUSER TUBE FLANGE
8574 M114
DIFFUSER TUBE
8574 M115
DIFFUSER TUBE SPIDER
8574M116
SCREEN CLAMP RING TOP STANDOFF
8574M117
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SCREEN CLAMP RING BOTTOM STANDOFF
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20; 6 REQ'D
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3. PROVIDE HOLES THROUGH WALL
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8574 M 154
UM 8574 M 155
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UM 0574 M 156
8574 M 156
UM 8574 M 157
8574 M 157
8574 M 158
8574 M 159
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8574 M 161
8574 M 162
8574 M 163
IMDEM
TITLE
ASSEMBLY (List ol Materials)
ASSEMBLY
TOP WELDMENT (Ult of Materials)
TOP WELOMENT ^
MIDSECTION WELOMENT (List of Materials)
MIDSECTION WELDMENT
BOTTOM WELDMENT (List Of Materials} •
BOTTOM WELDMENT
BAFFLE WELDMENT (List of Materials)
BAFFLE WELDMENT
COKE SCREEN WELDMENT (List of Materials)
CONE SCREEN WELDMENT
BAFFLE FLANGE WELDMENT (List Of Materials)
BAFFLE FLANGE WELOMENT
BAFFLE TRAY WELDMENT (List of Materials)
BAFFLE TRAY WELDMENT
BAFFLE SPACER LEG
CONE SCREEN RING
CONE SCREEN
CONE SCREEN SOCKET
BAFFLE FLANGE
BAFFLE TRAY RING
HYNOL
ZINC OXIDE
DESULFURIZATION VESSEL
F-205
A.E.C. PROJECT • N©^ HS74
Prepared , by
ACUREX BMRONMENTAL
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MOUNTAIN VIEW, CALIFORNIA
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REVISIONS
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SECTION A - A
NOTES:
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SEE L/M 9S74M1S7.
SECTION B-B
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REFERENCE DRAWINGS
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REFERENCE OftAWTNOS
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BOLT HOLES SHALL STRADDLE
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SEE NOTE 2
(0-25* REF.
TYP. OF 2
PLACES)
ALL DIMENSIONS REFERENCED TO
THIS NOTE SHALL CONFORM TO ANSI
B 18.3 DIMENSIONS FOR CLASS COO
STEEL FLANGES.
THE RAISED FACES OF THIS FLAHGg
SHALL HAVE A SPIRAL SERRATED
GASKET SURFACE FINISH HAVING
FROM 24 TO <0 GROOVES PER INCH,
SERRATIONS SHALL BE CUT US'NQ A
TOOL WHICH HAS AN APPROXIMATE
0.06" OR GREATER RAtMUS. THE
RESULTANT SURFACE SHALL BE
JUDGED BY VISUAL COMPARISON
WITH AARH STANDARDS (SEE ANSI
B <6.1). THE FINISH SHALL HAVE A
MAXIMUM 250 MICROfNCH
ROUGHNESS.
SEE NOTE 2 (018-25' REF.)
SEE NOTE 2 (0 1J0' REF
TYP. OF 2a EQUALLY SPACED)
SECTION
SEE NOTE 2 ( 0 20.75* REF.)
Aeurex Environmental Corporation
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HYDROGEN SULFIDE OESSICANT VESSEL S-102
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REFERENCE DRAWINGS
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SECTION A-A
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HYDROGEN SULFIDE DESSICANT VESSEL 8-102
BAFFLE TRAY RING
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REVISIONS
REFERENCE DRAWINGS
-------
INDEX
Drawing No. Title
871-01P Assembly of Feed System
6T1-02P 3 View of Feeder - Part A
671-03P Plan, Top, Injector Details
671-04P Metering Screw Details
871-05P Meter Screw Drive Details
HVNOL
BiOMASS FEED SYSTEM
111-801, T-805, SF-80G
Prepared by
Thomas R. Miles
Consulting Design Engineers
5475 W. Arrtwwood Lane
Portland, Oregon 87225
-------
iip \\
ill
B-92
-------
B-93
-------
-=#•
lJ2>
' -1*
-------
B-95
-------
-------
ROTATING DISC VAU/ES
• Temperatures to 1500 + F * Pressures to 10,000 pslg * Abrasives * Corrosives * Coking * Slurries
• High Cycling * Bl-Dlreetlonal « Intrinsically Fire Safe
B-97
-------
OVER 80 YEARS OF FIELD PROVEN SERVICE-
wrm APPLICATIONS WORLDWIDE.
PROVEN CONCEPT Starting In
1904 the unique rotating shearing
disc concept was the standard for
steam locomotive boiler blowdown.
Following this the packaged boiler
Industry has also accepted the
Everlasting quick opening valve
where our repulation remains un-
challenged, The valve handles
boiler blowdown, scale, chemicals,
high pressures, temperatures, and
flashing condensate, they have an
average life of 16 years.
Our slurry valves ere installed
throughout the world in processes
that are abrasive, corrosive or foul-
ing and that have high pressure,
temperature or cycling. The unique
self lapping meiaJ to metal seat de-
sign provides repeated tight shutoff
in severe service, while sealing
improves with use.
PRINCIPAL OF OPERATION The
actuator moves ihe stem and
lever arm a quarter turn which
drives the disc. The entire seal-
ing surface of the disc Is con-
stantly In contact with the seat
or pad through force exerted by
coiled springs. These springs allow
the disc to move vertically. This
compensates for thermal expan-
sion and contraction of the valves
components also overcoming the
effect of any back pressure for
which it was designed and prevents
particles from lodging between the
sealing surfaces. Differences in
tangenlial disc to seat friction forces
cause Ihe disc lo rotate on its seat
11.%^
as the valve cycles, thereby shear-
ing and wiping away any process
material that may accumulate. No
Other valve is similar.
FEATURES AND BENEFITS
^ UNIQUE ROTATING'
SHEARING DlSC-StfT
taf>p^d^1eftfianoadi«a1ciearir$
actio*, cuts m«5ugft »ofids, tanu
lasting bght SfefHStL
2. METAL TDWETA1
SEATING - abrasion
resistance, <*>de ia*np«r.
aura rang*.
3. WIDE BANO SEAT.
ING - pressure
capacity, tw-* aaaling
than industry slandanls,
to** Sslrifcutee over larger
area, less mm w*ac
4. FULL PORT — a&riston
fwtrtance. no odstaicfcOfi to
ltow. rnWmaf pressure drop-
5. ROTATING STEM -
bweased pacfcrifl fte,
wide selection of aou&torv.
«. SELF DRAINING
BODY-RaC*»i chance
due to material
tfl&ainmertS, lunation and
degrades*.
7. BOOYPURGE
CONNECTIONS-AMty
Id flush vata and
internals «NW n opertOoa,
8. SPRING LOADED CONNECTION
BETWEEN DISC AND DRIVE
tisc io compensate taf thermal encpamtoft
or contraction, adjusts Ior wees, mwurm
bght shot-off, resets bat* pressure,
ft FLATSEATinQ SURFACES—Ease
of maintenance.
10. REPAIRABLE SEAT-
inventory, leu maHrbmnanoe
1t STEM SEARINGS -The**
and sleeve baaringa iSgn item,
mwinuB pasting fcf#. aa*a
ac&atfri retiuct maintenance.
i2. DESfGN smpucry/
ft RSATtLfTY - Urtmal par*, «c*e of
iMjnunarioa, tons terwsi Ma, adipia&is.
m
STOEAMUNIO MOVING RWTTS are mads lo
. move lively through tfw ilurry with a mini-
I mum of insistence to operation, this design
1 ' can also bt lu-Tijhea as a ta*k bottom valve.
THREE WAY, DIVERTING,
OR CONVERGING. This valve
Is (Down In cut configuration
¦ultaUa lo 300 pslo. FabricitwJ
version Is available tor higher
pressures and temperatures.
a&R
B-98
-------
DURABILITY AND PERFORMANCE FOR
SHUT OFF AND ISOLATION APPLICATIONS
SELF LAPPING, WEARS IN-NOT
OUT Rotation ol the disc produces
an action that in the process me-
dium renews and polishes the metal
seating surfaces with each opera-
lion. This concept is unique causing
the Everlasting valve to wear In with
use white all other valves are busy
wearing out
TIGHT SEAL ASSURED The wide
seat and disc surfaces are routinely
machine lapped during manufac-
ture within several light bands of
flatness. This produces a seal that
Is better than Industry standards for
SHUTOFFand ISOLATION valves.
(Refer to graph). Precision lapping
and factory cycling of the valve can
reduce leak rates further.
CONSTRUCTION
SIZES: %* to 24*
END CONNECTIONS;
. Screwed, flanged, socket
and butt weld
BODY MATERIAL:
Cast Iron/Ductile Iron
Carbon Steel
Stainless Steel
Weldable Alloys
Packing/Seals
Grafoil or PTFE
DISC/SEAT MATERIAL:
Stellite #6
440C Stainless Steel
BASIS OF DESIGN:
Vacuum to
10,000 PSIG
ANSI Classes
150, 300, 600,
900,1500, 2500
TEMPERATURES:
-350 F to 1500+F
ACTUATORS: |
Manual Lever
Manual Wheel
Pneumatic
Hydraulic
Electric
PROFS/MM
ALLOWABLE LEAK RATES
SHUTOFFAND ISOLATION VALVES
t-fiATA- :R©V -fteSPEOTVE-wDCfr
(COPfeS AVAILABLE
ON RE
J ANSI
• API 598
DIN 32 ID
STING
» -TMfMiec wow
»to 'ooaeyetfs
»iyESiZEV*\. z 4* 6' 8' 10" 12* W tr ir
£*•*111*19 Vatars iiandartf mtntffackinriG praetctt produce a MMU tul mwames ANSI. Aft. an* OW erflefai
SELF CLEANING The valve tody
openness provides space for the
product to be freely displaced by the
lever arm and disc with each cycle.
Fines can not compact in small open
areas and possibly jam components
as Is the case with other valve con-
cepts. Each time the valve opens
lo discharge product, a vortex Is
caused by the eccentric body to port
configuration.
The settled
media swirls;
thereby clean-
ing the valve's
interior.
BI-OIRECT10NAL
tiotfbtetiisc config-
uration controls flow
in both directions.
m,&mi
B-99
-------
COMPUTER AIDED DESIGN &
ROBOTIC WELDER
COMPUTER AIDED DESIGN
The engineers utilize CAD and
advanced SUN hardware to create
valves that will reduce and simplify
your plant maintenance while pro-
viding tight shut-off for processes,
personnel safety, and to meet en-
vironmental regulations. The in-
herent quality control of CAD
assures exact dimensions in all
parts and assembly drawings.
Tolerances are precisely assigned
and cross checked electronically,
eliminating human error. Drawings
are produced by electronic plotters
and laser jet printers ensuring
quality and accuracy tor manufac-
turing interpretation.
ROBOTIC WELDER
Provides consistent full penetra-
tion code certified welds through
computerized control." The manu-
facturing process incorporates In-
novative and proven procedures
and technology.
PRODUCTS & MATERIALS
THE UNIQUE EVERLASTING con-
cept has been incorporated in six
distinct product lines,
• SLURRIES .Abrasive Particulate
• BOILER BLOW DOWN
• JACKETED
• STEAM SERVICE
• FIRE PROTECTION
• ABRASIVE SOLIDS
These products provide exceptional
service in systems where abrasive
and corrosive materials such as the
following are transported through
piping systems.
COKING HYDROCARBONS
CATALYSTS
STEAM
COKE
COAL/COAL SLURRY
TAR/TAR PITCH
TITANIUM ORE
TITANIUM DIOXIDE
SILICON
TAIL GAS
WOOD CHIPS
SHALE
FLY ASH/ASH SLURRY
LIMESTONE
ALUMINUM
ALUMINA
COFFEE GROUNDS
SULFUR
SAND
MINE TAILINGS
SILICA
FLAMMABLE LIQUIDS/GASES
BOILER WATER
MAGNESIUM SULPHATE
DIATOMACEOUS EARTH
OTHER ABRASIVES OR
CORROSIVES
WALVE
^COMPANY INC.
La 7 «T,'¦/F„
108 Somogyi Ct, South Plaintietd, NJ 07080 (908) >69-0700
A Fax; (SO8) 769-8697
A subsidiary of Armstrong International Inc.
BARRETT EQUIPMENT CO.
4111 STONE WAY NORTH
SEATTLE, WA 98103
(206)634-1776
B-100
------- |