Assessment of materials selection and performance for direct-coal- liquefaction plants in the United States

Several direct coal liquefaction processes have been demonstrated at the pilot plant level in the United States. Presently only one plant remains operational, namely, the Hydrocarbon Technologies, Inc., 4.0- ton-per-day process development unit in Lawrenceville, New Jersey. The period from 1974 to 1982 saw the greatest amount of development of direct coal liquefaction in the United States with four major pilot plants being devoted to variants of this technology. The plants included the SRC-I plant at Wilsonville, Alabama, which operated from 1974 to 1992; the SRC-I/II plant at Fort Lewis, Washington, which operated from 1974 to 1981; the H-Coal plant at Catlettsburg, Kentucky, which operated from 1980 to 1982; and the Exxon Coal Liquefaction Pilot Plant at Baytown, Texas, which operated from 1980 to 1982. Oak Ridge National Laboratory scientists and engineers were actively involved in many phases and technical disciplines at all four of these plants, especially in materials testing, evaluation, and failure analyses. In addition, ORNL materials scientists and engineers conducted reviews of the demonstration and commercial plant designs for materials selections. The ORNL staff members worked closely with materials engineers at the pilot plants in identifying causes of materials degradation and failures, and in identifying solutions to more » these problems. This report provides a comprehensive summary of those materials activities. Materials performance data from laboratory and coal liquefaction pilot plant tests, failure analyses, and analyses of components after use in pilot plants were reviewed and assessed to determine the extent and causes of materials degradation in direct coal liquefaction process environments. Reviews of demonstration and commercial plant design documents for materials selections were conducted. These reviews and assessments are presented to capture the knowledge base on the most likely materials of construction for direct coal liquefaction plants. « less