Coal Liquefaction Technologies-Direct and Indirect Routes: Theo L.K. Lee

Coal Liquefaction Technologiesdirect and indirect routes
Theo L.K. Lee

Headwaters Technology Innovation Group
Lawrenceville, New Jersey, USA
APEC Clean Fossil Energy Technical and Policy Seminar

Jan 26-28/05 Cebu City, the Philippines
APEC Clean Fossil Energy Tech. & policy seminar: Jan 26-28/05
adding value to energy
Scope of Presentation
Coal liquefaction routes
Properties of products from direct and
indirect routes
Hybrid plant concept
China Projects
Concluding Remarks
Coal Liquefaction Routes

Direct Coal Liquefaction
Partial dismantling of the coal structure

High temperature & high H2 overpressure
Refining of raw coal liquids
Coal only
Coal/oil co-processing
Indirect Coal Liquefaction
Complete destruction of the coal structure

Gasification to produce syngas (H2/CO)
Removal of hetero-atoms (S, N)
Catalytic synthesis of ultra clean fuels or chemicals
Direct Coal Liquefaction Processes

1st Generation: IG Farben (Germany)
2nd Generation: SRC, EDS(250), H-Coal (600)
Breckinridge H-Coal Commercial conceptual design
3rd Generation:
USA: CTSL, ITSL, HTI
Japan: BCL(50), NEDOL(150)
Germany: IGOR
British: LSE
Note: Value in bracket is pilot plant capacity in ton/day
600 TPD H-Coal

Pilot Plant, Catlettsburg,
Kentucky, USA
600/
H-Coal
Catlesttsburg
Direct Coal Liquefaction Process

H2 S, NH3 ,
COX
RECYCLE H 2
MAKE-UP
H2
COAL
LIQUEFACTION
COAL,
CATALYST
C1 - C2
GAS RECOVERY
TREATMENT
LPG
GASOLINE
HTU
REFINING
DIESEL
FUEL
H-DONOR
SLURRY
SLURRY
DAO
FRACTIONATION
HVGO
SOLVENT
DEASHING
ASH
REJECT
Economic Comparison
Case
Reactor Type
Yield, bbl/ton
H2 Used, SCF/bbl
Refinery Integration*
Coal
Slurry
4.0
7,120
OIL
Slurry
5.2
2,130
Coal/Oil
Slurry
4.7
3,180
Coal/Oil
Ebullated
5.0
3,570
Investment, US$MM
ECOP, US$/bbl
1,076
22.7
479
15.1
566
18.1
597
18.0
1,666
32.2
1,102
22.9
1,126
26.2
1,176
25.8
-------
11,660
1,724
19.6
10,580
1,633
22.6
9,640
1,595
22.9
Grass Root Plant*

Investment, US$MM
ECOP, US$/bbl
Grass Root Plant

Max. Throughput, TPD
Investment, US$MM
ECOP, US$/bbl
ECOP Equivalent crude oil price
(1996 dollars), US Gulf coast
location
DCL Feasibility Studies on Chinese

Coals
Enlisted in Chinese 9th and 10th Five-year plans
Production of coal derived liquids received top priority
Initiated three DCL studies in 1996/7
Yunnan Xianfeng brown coal IGOR Process
Heilongjiang Yilan bituminous coal NEDOL
Process
Inner Mongolia Shangwan bit. Coal HTI &
NEDOL Processes
Signed process license with HTI in Jun/02
Shenhua Inner Mongolia DCL Project

Coal feed:
12,800 TPSD
Liquid yields: 50,000 BPSD
Technology: HTI Coal Process
Catalyst:
Fe based
Reactor: three backmixed slurry catalyst reactor trains
Economic:
Coal cost: $10 to 15 per metric ton
$26/bbl equiv. crude oil price
$2.2 billion capex
Status:
Nov/02 HTI completed process design package

June/03 Axens completed basic engineering design package
Detailed engineering underway
Site preparing since mid-2002; reactor being erected
Late 2007 plant startup
Shenhua Accelerates Synfuels Production

Dr. Zhang, Yuzhuo
Assistant General Manager of Shenhua Group
Chairman, Shenhua Coal Liquefaction Corp.
Production Plan
2007
2010
2015
2020
3.2 mm TPY DCL liquids

5.0 mm TPY DCL liquids
20 mm TPY DCL/ICL liquids
30 mm TPY DCL/ICL liquids
10
Other DCL Studies in Asia

BPPT evaluation of East Kalimantan coals (CCUJ
/JICA) - completed
Oil India Limited pre-feasibility studies on Assam coal
(HTI, Axens) in progress
11
Shenhua Coal Derived Liquids

Properties
(5%, 90%)
Density, g/cm3 (20oC)
Viscosity, mm2/s (20oC)
S, ppm
N, ppm
Cetane No.
Acidity mgKOH/100ml
Oxidation Sludge, mg/100ml
Flash Point, oC
Cold Filter Plugging Point, oC
Solidification Point, oC
Compound Class Type Analysis, w%
Paraffin
Naphthene
Aromatic
- Shi, Yuhua (RIPP, Oct/04)
Naphtha
Diesel
(99,159oC )
(195, 277oC)
0.7641
<0.5
<0.5
0.8648
3.69 (3 ~ 8)
<5 (<2000)
<1
46.7 (>45)
0.4 (<7)
<0.3 (<2.5)
76 (>55)
-9 (<-5)
-26 (<-10)
26.7
68.3
5.0
13.3
81.9
4.8
12
Indirect Coal Liquefaction Processes

Fischer & Tropschs early works in 1940s.
SASOL (South Africa): >150,000 BPD
Synthol (high temperature; C1-C15)
Slurry Phase reactor (low temperature, liquid + wax)
Shell SMDS (Malaysia): 500,000 TPY

Syngas to methanol and Diemethyl Ether (DME)
Mobil methanol to gasoline (New Zealand): 800K TPY
Lurgi methanol to propylene
13
Fuel/Power Co-production Facility

Coal*
Oxygen/
Steam
Gasification
Gasification&&
Gas
GasCleaning
Cleaning
Iron Catalyst
H2 + CO
Syngas
FT
FT
Synthesis
Synthesis
CxHy
Liquids
& Wax
FT
FTProduct
Product
Separation
Separation
&&Upgrading
Upgrading
Steam Tail Gas
Sulfur,
CO2
and Ash
Steam
*Any carbon-bearing feedstock
Electric
Electric
Power
Power
Generation
Generation
Ultra-Clean
Water
Liquid Fuels
and
Oxygenates & Chemical
Feedstocks
Electricity
Note: FTD quality is not dependent on the
type of feed used to generate the syngas
14
GTL is Commercially Proven

SASOL (S. Africa)
44 years commercial
160,000 b/d+
Feedstock Coal
SASOLS SOUTH AFRICAN FACILITY
MossGas (S. Africa)
10 years commercial
22,500 b/d+
Feedstock Natural
Gas
Shell (Malaysia)
7 years commercial
15,000 b/d+
Feedstock Natural
Gas
15
Rentechs Pueblo, Colorado GTL Plant
16
Indirect Coal Liquefaction Projects

Numerous methanol and DME projects in operation or
in progress
China initiated co-op. discussion with SASOL in 2004
3mm TPY Shaanxi ICL Project (Shenhua Group)
3mm TPY Ningxia ICL Project (Ningxia Coal Mining Group)
US DOE co-funded 5,000 BPD FT project in

Pennsylvania
Illinois Royster-Clark fuels-ammonia co-production
project
Western coals fuels-power co-production feasibility
studies
17
FT Diesel an ultra clean fuel
paraffinic
Cetane No. >70
Zero Sulfur
No aromatics
18
FTD is an Ultra Clean Transport Fuel

(diesel)
Low Sulfur
D-975
California Rentech/HTI
CARB
(ICL)
EU
(2005)
EPA
(2006)
Cetane Index
>40
>48
72
>50
>40
Aromatics (vol %)
<35
<10
<1
<10
<35
Sulphur (ppm)
<500
<500
<1
<10
<15
Biodegradable
NO
NO
YES
NO
NO
Note: In 2006, US regulations will require <15 ppm sulphur

19
FT Diesel Exhaust Emissions

are Lower than Typical #2 Diesel
Emissions Relative to a
Typical Diesel Fuel (Percentage)
-5
-9
-10
-15
-20
-25
-28
-30
-33
-35
-40
-45
-42
Hydrocarbon
CO
N0x
Particulates
20
FOB Diesel Cost ($ Barrel)
Cost Estimates for FT Diesel

Coal & Coke
Current CARB Diesel
Natural Gas
63
42
21
0.50
1.00
1.50
2.00
2.50
3.00
3.50
Feedstock Cost ($/mmbtu)

21
Hybrid Coal Liquefaction Plant Concept

DCL produces good quality naphtha for gasoline but
distillate requires significant ring opening to meet
diesel specs.
ICL produces good quality distillate for high quality
diesels but FT naphtha requires considerable refining
(alkylation, isomerization and reforming) to meet
gasoline specs.
Gasification is needed in both process.
Better energy efficiency is anticipated in an integrated
DCL and ICL plant
22
Hybrid Plant Concept

Gasification
Raw FT products
Fischer Tropsch
Synthesis
FT tail gas
Recovery of
Hydrogen
H2
Product Blending
and Refining
H2
Coal
Final
Products
Direct Coal
Liquefaction
Raw DCL products
23
Hybrid Plant: Product Components

100,000 BPSD Total products
Gasoline Blending Pool
Direct Reformate
Direct Stream Naphtha
Straight Run FT
Alkylates
Alcohols
Butanes
Diesel Blending Pool
Direct Diesel
Indirect C12-C18
Indirect C19+
BPSD
Volume, %
25,710
12,510
20,510
4,220
1,190
930
39.5
19.4
31.5
6.5
1.8
1.4
10,850
16,760
7,220
31.2
48.1
20.7
24
Hybrid Plant Overall Summary
Coal Input (TPD mf)

Liquefaction
Gasification
Total
Yield, bbl/ton
Thermal Efficiency, %
(HHV basis)
Estimated Product Characteristics
Ring Compounds (%)
(gasoline/diesel)
Density, lb/bbl
Hybrid
Direct
Indirect
11,823
26,601
38,424
2.60
22,708
16,463
39,171
2.55
0
45,207
45,207
2.21
65.0
63.2
56.4
32/2
269/272
33/5
279/289
29/0
249/275
25
Hybrid Plant Overall Summary

Relative Economic Data
Total Capital
Coal Cost
Total Operating Cost
Required Selling Price
Hybrid
Direct
Indirect
1.031
1
1
1.0
1.018
1.057
1.135
1.160
1.137
1.008
1.093
26
Concluding Remarks
Under the current high oil price and unstable supply
scenario, coal-to-liquids is a viable option for
providing clean transportation fuels and petrochemical
feedstocks
Coal/Oil co-processing is a lower cost and lower risk
option for introducing coal liquids
Hybrid coal liquefaction plant improves overall
efficiency through reduction in refining cost
27

Coal Liquefaction Technologies-Direct and Indirect Routes: Theo L.K. Lee

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Coal Liquefaction Technologiesdirect and indirect routes

Theo L.K. Lee

APEC Clean Fossil Energy Technical and Policy Seminar

adding value to energy

adding value to energy

Coal Liquefaction Routes

Partial dismantling of the coal structure

Indirect Coal Liquefaction

Complete destruction of the coal structure

adding value to energy

Direct Coal Liquefaction Processes

Note: Value in bracket is pilot plant capacity in ton/day

adding value to energy

600 TPD H-Coal

adding value to energy

Direct Coal Liquefaction Process

adding value to energy

Grass Root Plant*

Grass Root Plant

adding value to energy

DCL Feasibility Studies on Chinese

adding value to energy

Shenhua Inner Mongolia DCL Project

Nov/02 HTI completed process design package

adding value to energy

Shenhua Accelerates Synfuels Production

3.2 mm TPY DCL liquids

adding value to energy

Other DCL Studies in Asia

adding value to energy

Shenhua Coal Derived Liquids

- Shi, Yuhua (RIPP, Oct/04)

adding value to energy

Indirect Coal Liquefaction Processes

Shell SMDS (Malaysia): 500,000 TPY

adding value to energy

Fuel/Power Co-production Facility

Steam Tail Gas

*Any carbon-bearing feedstock

adding value to energy

GTL is Commercially Proven

SASOLS SOUTH AFRICAN FACILITY

MossGas (S. Africa)

adding value to energy

Rentechs Pueblo, Colorado GTL Plant

adding value to energy

Indirect Coal Liquefaction Projects

US DOE co-funded 5,000 BPD FT project in

adding value to energy

FT Diesel an ultra clean fuel

adding value to energy

FTD is an Ultra Clean Transport Fuel

Note: In 2006, US regulations will require <15 ppm sulphur

adding value to energy

FT Diesel Exhaust Emissions

adding value to energy

FOB Diesel Cost ($ Barrel)

Cost Estimates for FT Diesel

Current CARB Diesel

Feedstock Cost ($/mmbtu)

adding value to energy

Hybrid Coal Liquefaction Plant Concept

adding value to energy