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Printed in Cheat Britain.
PRESENTED
AT
CHEMICAL
0009-2509188
$3.00 + 0.00
0 1988 Pergamon Press plc
1427-1435.1988.
THIRD
P. V. DANCKWERTS
MEMORIAL
LECTURE
THE INSTITUTE
OF DIRECTORS,
4 MAY
1988
ENGINEERINGS
OCTAVE
Chemical Engineering Department. Oregon
GRAND
Direct
ethanol
scale
up
5%
cOnverSIOn
I-z
+
ADVENTURE
Dehydrogenotion reaction
I-
U.K.
LEVENSPIEL
State University, Corvallis, OR 97331-2702, U.S.A.
Reactant -
LONDON,
Liquid lndlum
-450=X
-
acetaldehyde
-
2 - butanol
cyclohexonol
MEK
-
Isopropanol -
Ll3
cyc10hexon0ne
ton/day
of feed
acetone
Slide 1.
reactIonboats
per tube
Slide 2.
1427
1428
OCTAVE
,,f-at
/
indium
Slide 3.
Spray
column
Everything
at 450C
--
Slide 4.
SLC - supported
catalysts
liquid
MIX -
PelW
1ze
carc1ne
-8CUs:
WS
>%
98
Reduce
cmvers,o
wth
LEVENSPIEL
Hz
-4ooC
Specks
03-
of
In
Operate
20$.,,
1
Pack
to
and
hecat
350C
Slide
5.
Tmlnlng
of
US Pat # 4.224.190
Reactant
with understanding
* Handle
Make
emergencies
lmpmvements
Theory
developing
Language
new processes
Innovations
- New
catalyst
New
reoctlon
New
contoctlng
pathways
patterns
Slide
6.
Chemical engineerings
Liquid
fuels
from
moving
Downflow
shale
1429
grand adventure
Raw shale
beds
Volotiles
RCIW
step I
shale
Heat,
rnck
1
no q lr
tieat
released
may
X-e--
Paroho
Klviter
Tosco
feed
In
used
be
step
to
_____-x
stepl
(II
or product
8 Petrosix
Slide 7.
shale
some
Air
go=
rn i.d.1
Cold product
gas
V
Spent shale
Slide 9.
Superior
Oib
horizontal
moving
bed
(merry
-go - round)
ws
Slide 10.
Unocals
IGT
Poroho
Counterflow
moving
Occidental
union 011
beds
Hot recycle
upflow
moving
bed
~0s
Pet robros
cross f low
n-wing
beds
Kerr - McGee
Kwiter
Superior Oit
Cities
Chevron
Clrculoting
solid schemes
Downflow
of
LUrQl
AX0
Shale
Qas
Shell
solt
Slide 8.
by V. D. Allred 1
1982
ze
*---Rock
shale
Slide 11
pump pushes
upward
+ C
1430
OCTAVE
LEVENSPIBL
Tosco II
(ball
l-l
Chevrons
Elevator
.I
STB
turbubnt
bed)
I
3:
__
(staged
miW
Lift
carbon
pipe
burn
UP
Raw
shale
/
c
I-bt
waste
gas
Slide 14.
_ Downflow
-bust
lift
aon
of
energy unextracted.
On the other hand, the
fluidized-bed processes are more complicated, but
in most cases they are designed to extract all the
energy from the shale.
Some designs go to great lengths to recover the
energy from the fixed carbon. As an example Slide
15 shows U.S. Shells concept. The left half of the
slide with its two fluidized beds and its circulating
heat-carrying steel balls has just one purpose, to
transfer heat from hot spent shale to fresh cold
shale.
Look at the designs of Slides 12, 13 and 15. In
their very different ways they all try to recycle heat
from spent shale to fresh shale. Thus solid-solid
heat exchange is the problem here, and an efficient
way of doing this may then be the key to a good
shale process.
We chemical engineers are quite comfortable with
fluid-fluid heat exchange. There are books upon
books on this subject. But what about solid-solid
heat exchange? There is hardly anything on this
soltds
I -3cm/s
p*pe
Solids
rotio
recycle
= 2-
Slide 12
Lurgi - Ruhrgas
(meatgrinder)
IL1
Shells
Spher
_..-..
Ti
Solid
and
recycle
rotio
= 2 -
bed concept
Hot balls
- -/
fuel
Slide 13.
Siide 15.
Chemical
engineerings
Cooted fluidized
solids out
Hwted fluldized
solids out
Slide 16.
Potters fluidized
exchanger
l-lot
Cold
sol Ids
solids
Slide 17.
1431
grand adventure
heat exchanger
0C
48C
100C
52C
(El
Upflow
of condensate
Slide 18.
this arrangement represents cocurrent heat exchange for which the maximum heat recovery
efficiency is only 50%.
Of course if we are able to coax one stream of
solids to flow upward then we could approach 100%
efficiency. But how do you coax solids to flow
upward on their own? However, there is a simple
alternative. Rearrange the heat pipes as in sketch B
of Slide 18. This results in a downflow of both solid
streams with counterflow heat exchange and close to
100% heat recovery efficiency. Even better still,
locate the cold unit above the hot unit, as shown in
sketch C. Then the working fluids in all the heat
pipes condense in the upper unit and flow down to
the lower unit, a more efficient arrangement.
So why not consider incorporating heat pipes into
a shale process. Slide 19 shows a possible design.
With no need for very fine solids, no fluidizing gas,
gravity flow of solids throughout the exchanger
section, a process with this type of heat exchanger
should be much simpler than many of the present
designs on which so much effort and money have
been spent.
In looking at all these different ways of extracting
oil from shale rock-in
fluidized beds or moving
beds, using upflow, downflow or horizontal flow of
shale, with or without using inert heat-carrying
solids-it
should be evident that it is the first step in
the development of a process, the choice of process
concept, that we are considering here. Maybe youll
agree with me that this is the crucial step in the
development of a process, because once the process
concept is chosen it determines the path to be taken
in all the supporting research, testing, development
and design which follows.
In general terms, not just for shale processing,
what Id like to suggest is that before starting work
OCTAVE LEVENSPIEL
1432
DMB.HPC
Cold
row
downf low
bed heat
concept
stale
moving
pipe
(+I
No
on
(+)
remains
solids
No
N2
VOlOtlleS
I+1
No
(+)
Can
fuel
needed
handle
Large
solids
(+)
Cold
spent
S1mpte
shale
Slide 19.
on a particular process concept one should set out
the criteria for the ideal-never
mind whether
practical or not-and
then see how close one can get
to the ideal. This requires
thinking
research,
sitting around in easy chairs, discussing and discussing-all
this before building even the smallest of
pilot plants.
Lets try this type of thinking with another system,
the production
of synthesis gas from coal. This is
likely to become one of the most important processes worldwide
by early next century as coal will
progressively replace petroleum as the feedstock for
organic chemicals.
Slide 20 shows. in simple terms, that two reactions
are involved: the desired reaction of coal with steam
which is endothermic,
and a combustion
reaction
which supplies the heat for the desired reaction.
And since this would be a large-volume
operation
wed
like to use only cheap easily obtainable
feeds-air,
water and coal, and nothing else.
Synthesis
The
gas
rdeat
from
process
coal
should
only
use
Requirements
COAL.
AIR
and
(+I
Onky
(+I
No
N,
+Q
(+I
No
tar
or liquid
(+I
No
O2
plant
Coat +
(+I
A11
flow
steam e
t;;:r,
CO
CO,
H,
+ (N,)
30
(+I
How
to
run
these
two
reactions
Slide
ideal
an
synthesis
gas process
WATER
Desired
Cool
for
20.
se
WATER
opemte
to
streams
must
be
and
and
with
leaves
Process
to
AIR.
COAL
product gas
formed
be
used
Leave
at
slmpk,
room
procticol,
control
SIide
21.
tempemture
and
easy
1433
gasification
- Brltlsh
concepts
Gas/Lurgi
Dry ash
SlagQlnQ
Lurgl
Gas lntegrote
IGI - two stage
moving
bed
fluldized
bed
beds
I
Entrained
gasi f iers
Also
fluldized
Hot zone
Air
Air
Air
Air
02
Air
Air
A,lr,
Air
Ponindco
Ruhrgas VOrtex
Shell - Koppers
Texo co
Air,
Air
Air,
Air,
Molten
0,
0,
0,
0,
Air
4
0,
Corp., krk
-Air
Cool
NoyeS
CO+Hz.
N,
zone
Ash
Scheme
Tars
O2 plant
(+I
No
tar
(+I
No
0,
(+I
Sample
&
plant
(-1
N,
(-1
Hot
with product
products
I
Air + steam
tar
.- - Ropld
coollg
l-lot
(-1
(- )
Slide 22.
Coal
product
Scheme 3
N,
==%I
Concepts:
Cool
with product
CO + H,.
0,
0z
baths
Goslflcation
N,
Scheme
3 (Slide 2s) shows that nitrogen separation is the problem with single fluidized bed
processes, but not tar production,
because the
product gases stay hot for a reasonably long time.
Scheme 4 (Slide 26) keeps the reactions separate
in two or more tluidized beds. Its main problem
concerns complexity, and the CO*-Acceptor process
shows what happens when this question is taken
lightly.
There are many variations of these four basic
designs, and we will not go into them. It suffices to
note that none of the processes proposed
or
operating today approach, in principle, the ideals
listed in Slide 21. This means that it may be
worthwhile trying to conceive a radically different
and better concept, and not just an improvement of
existing technology.
So, keeping the ideal in mind, lets see what we
can come up with. Here are two of more than a
dozen ideas that our easy-chair research group in far
Air
Bionchi
i2 stages)
01 - gas
Combustion Engineering
Foster - Wheeler
(2 stages)
Koppers - Totzek
Simple
Slide 24.
Air
CQQos
No
(+I
02
0,
(3 stogesj
(3 stages)
(5 stages)
(+I
(+
NZ
V
Ash
Air
osh agglomerating
Scheme
Ha.
&@$@
Onty steam
Only steam
Air
CD, - acceptor
Cogas
ICI moving turden
Westinghouse
Doto
Y
&3$x8
02
Wlnkter
From Cool
$2
0
008 R
%o _,
,g
*
,.oea
4
A1r
A1r
Air
Air
Babcock - W11cox
Bell - Aerospace
flow
O2
Power go*
Thyssen Galoczy
UGI water gos
Weltmon
GoCusho
Wellman - Incandescent
Woodoll Duckham
IGT
hygos
TrIgas
Mutt i
fluldized
beds
A1r
Air.
tar
0,
Battelle
Two
ftuidired
02
Air
u - gas
1
Air.
Air
Exxon
Hoffman
HRI fast
Synthone
one
0 0,000
With 0,
( USBM)
~erpely
Leuno
Large
CO
Cool
(+)
Simple
(+I
No O2
plant
Slide 25
(+ 1 Cool products
(-1
Tar
(-1
N, with
product
Scheme 4
CO+Hz
N, + COz
(+I
No
(+I
No
N,
In
product
tar
(+ ) No Oz plant
needed
+ air
Slide 23.
Scheme
2 (Slide 24) shows how the nitrogen
problem is avoided, but unfortunately at the cost of
an upstream oxygen plant.
Steam
Ajr
Slide 26.
(-1
Not
(-1
Hot product
simple
OCTAVE LEVENSPIEL
1434
(exchanger
- gasifier)
concept
/COz+
Slide 27.
RE - GAS
N,
t
(regenerator
CO,
H, +
co
t
tool
Hot
Powdered
Heating
Coal
Powdered CQQLf
(l,r
step
Gasif ication
Slide
28.
step
steam
Nz
Chemical
engineerings
again and again until they all enthusiastically agree that theyve come up with the
very best.
(3) tt may be risky to start out with small bench
scale pilot plants without thinking through the
whole operation, because as one progresses
one has more and more invested in following
the path which has already been chosen-not
just money invested, but intellectual effort
and reputation. A momentum is developed to
follow a given path which makes it more and
more difficult to change direction, to admit
that some other way may be better and that
one should maybe start afresh in a different
direction.
(4) Some may suggest, especially after looking at
all the wildly different designs on Slides 8 and
22, that my whole discussion today may not
be pertinent because the difference in processing costs may represent only a minor
factor in the overall economics. However, in a
large-scale operation I doubt that this is so.
(5) To go back to the start of my talk, I pointed
out that the development of a process represents a two-step affair, thinking up a good
scheme and then transforming it into reality.
In chemical engineering education we focus
on the second step, and the way we teach this
is with courses of lectures. But would this
teaching method work with the first step?
meet
grand adventure
1435