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TAIL GAS VALORIZATION BY PRODUCTION OF ELECTRICITY AND HIGH PRESSURE STEAM AT CABOT PLANT BERRE FRANCE

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The CABOT Plant having as main object the production of Carbon Black from tar, was rejecting in the atmosphere, through a flare stack, considerable amounts of energy contained in the process tail gas. The quantities rejected were reaching 60 MW during 8000 hours.
The main purpose of the project is to ensure the greatest possible valorization of the energy contained in the tail gas through combined production of electricity and steam. It enables to realize the complete burning up of gas before evacuation in the atmosphere, and, procuring to the plant a powerful tool of electricity self-production, it permits the most performing modernization of the production lines.
Although the realization of the project has been interfered with at start by unforeseen events, such as the existence in the plant underground of accidental water creeping, the construction delays have been fully adhered to.
The problems have been solved thanks to the capability shown by the companies : the owner CABOT, the constructor ARMAND INTERCHAUFFAGE, assisted by the engieneering FOSTER WHEELER FRANCE, in focusing and solving the difficulties encountered in real time, and in taking the appropriate decisions to ensure the good completion of the work.
1. - This installation is mainly composed of :
- A recuperation boiler burning tail gas, natural gas being used as starting fuel and eventually as auxiliary. This Out Door boiler produces 93 t/h of 50 bar abs steam, overheated at 470 deg. This is the main technological innovation, the boiler having to function without support.
- A turbo-alternator, with a nominal power of 20 MW (maximum 22 MW) equipped with two tappings, the first set at 9 bars meant to cover the requirements of the Cabot Plant and of certain auxiliaries of the power plant, the second at 4 bars - not set - meant for heating up the thermic gas extractor. The alternator outlet voltage is 5.6 KV.
- A closed circuit aero-condensor, with 5 cells and two speed moto-ventilators, ensuring a 0.16 bar abs vacuum, under nominal functioning conditions.
- A group of high voltage electrical installations permetting : . to cover the whole requirements of the plant and of the power plant to the level of 20 KV, .to sell to Electricite de France, on its 63 KV network in priority, on the 20 KV network as relief, the excess energy produced by the turbo-alternator and not consumed by the plant and the power plant. - A centralized piping of all the power plant installations.
- The technical equipments auxiliary to the power plant, including a relay boiler of 10 t/h 10 bar steam and the masonry chimney with internal metal duct, 69 m high.
- The buildings sheltering the turbo-alternator, the electrical installations and the auxiliary installations, including the offices, the annex premisses and the control room of the power plant. - The buildings supporting the external installations.
- The networks for bringing the fluids, evacuation, the platforms and the roads to the power plant.
2. - No power generation from poor and damp tail gas gives high characteristical steam without support and additional gas.
- The high cost of the technology is due to the fixed equipment (refractory, gas circulation, exchanger) required to ensure the complete burning of a variable gas.
3. - Thanks to the support of the EEC (1 198 000 ECU)and that of the French Ministry for Environment (AFME), the installation will be self-financing inspite of the very low sales price of the electricity produced delivered to EDF through their network. The gross return time must not exceed 5 years.
4. - This technology is not comparaable to the classical techniques with which the defined objectives cannot be reached.

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CIE GENERALE DE CHAUFFE + FOSTER WHEELER FRANCE
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59350 SAINT-ANDRE
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