An Alternative Route for Coal To Liquids (CTL)...COAL TO LIQUID Date Sources: FT Date Sasol 2004...
Transcript of An Alternative Route for Coal To Liquids (CTL)...COAL TO LIQUID Date Sources: FT Date Sasol 2004...
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An Alternative Route for Coal To Liquids (CTL) applying Methanol to Gasoline (MTG) technology An Alternative Route for Coal To Liquids (CTL) applying Methanol to Gasoline (MTG) technology
Sam Tabak
ExxonMobil Research & Engineering
Stefan HamelMax Heinritz-AdrianAdrian Brandl
Uhde GmbH
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Oil and Coal Reserves (Worldwide)Oil and Coal Reserves (Worldwide)
• Proven oil reserves ~ 1,332 trillion barrels• Todays oil consumption ~ 85 million barrels / day⇒ proven oil reserves horizon at ~ 40 years
• Proven coal reserves ~ 905 gigatons• Todays coal consumption ~ 5 gigatons / year⇒ proven coal reserves horizon at ~ 180 years
⇒ Coal will by far outlast crude oil
⇒ Difference increases under consideration of estimated resources
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Crude Oil Price DevelopmentCrude Oil Price Development
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Crude Oil Prices recover from near-term decline in course of the world-wide financial and economic crises
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Crude Oil Price in Reference Case is projected to reach 130 USD/bbl (in 2007 dollars), respectively 189 USD/bbl (nominal dollars) in 2030
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Price Developments Crude Oil vs. Natural Gas vs. CoalPrice Developments Crude Oil vs. Natural Gas vs. Coal
⇒ On the contrary: Coal prices remain stable below 3 USD / MMBTU⇒ Feasibility of Coal to Liquids will continuously increase
Source: EIA Annual Energy Outlook, 2009, Early Release
Energy Prices, 2007 dollars per MMBTU
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Coal to Liquids is moving forwardCoal to Liquids is moving forward
• Shenhua Coal to liquids (DL); started-up end 2008
JAM Coal to liquids (MTG); start-up 1st half 2009
Baard Energy ORCF Project; Wellsville, Ohio
DKRW Energy CTL (MTG); Medicine Bow, Wy
TGDS CTL (PDQ + MTG), Mingo County, WV
• Further projects e.g. in India, Australia, South Africa etc.
• Focus in Europe on BTL
http://upload.wikimedia.org/wikipedia/commons/a/a4/Flag_of_the_United_States.svg
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Liquid Fuels
Options for Coal To LiquidsOptions for Coal To Liquids
Gasification MeOH MTG
Gasification F-T Refining
Coal
Gasification
DirectLiquefaction Refining
• All three routes: three step processes• Thermal efficiencies: essentially governed by the carbon hydrogen ratio of the feed
and the fuel products.
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Unique Shape Selective ChemistryUnique Shape Selective Chemistry
Methanol
Water
Gasoline
• Unique “Shape Selective” chemistry discovered in the early 1970’s
• Development done through the 70’s/80’s on a variety of process options
• Plant started up 1985 and operated successfully for ~10 years until conversion to chemical grade Methanol production
• Second generation Coal based plant scheduled for mid 2009 start-up in China
• Additional plant in Engineering for Medicine Bow, Wyoming
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MTG Was Commercially OperatedMTG Was Commercially Operated
Commercial 14500 BPD plant in New Plymouth New Zealand. Plant ownership 75% NZ Government and 25% ExxonMobil.
MTG SynGas and MeOH Generation
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2nd Generation MTG Technology2nd Generation MTG Technology
ExxonMobil is the world leader In catalyst development and we manufacture our own catalysts.
• Second Generation Design based on learning's from 10 years of NZ operation
• Improved heat integration• Improved process efficiency• Process re-optimized for coal-based
methanol
Reduced capital costReduced operating cost
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JAM MTG Plant, Jincheng, ShanxiJAM MTG Plant, Jincheng, Shanxi
2500 bbl/d plant as part of CTL demo plant; Start-up in 1st half 2009
Picture courtesy of Shanxi Jincheng Anthracite Coal Mining Group
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MTG Process Flow DiagramMTG Process Flow Diagram
LPG
Light Gasoline
FinishedGasoline
Treated GasolineHeavy
Gasoline
DME Reactor MTG Reactor(Multiple)
BlendingBlending
Compressor
C2-
Stabilized Gasoline
LPG
DeEthanizer Stabilizer StabilizerSplitter HGT Reactor
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Product and Process Simplicity for MTGProduct and Process Simplicity for MTG
DEWAX
NaphthaReforming
HDT/HDC
Fischer Tropsch Fischer TropschCo Catalyst @220C Fe Catalyst@340C
Fuel Gas 6 15 1.1LPG 6 23 10.0Naphtha 19 36 88.8 36.7Distillate 22 16 43.3Fuel Oil/Wax 46 5 20Oxygenates 1 5 0.1 0.34
MTG H-Coal™ Direct Liquefaction
HDT
NaphthaReforming
HDT/HDC
NaphthaReforming
HDT/HDC
PolygasProcess
Recovery
REF
INER
YC
OA
L TO
LIQ
UID
Date Sources: FT Date Sasol 2004 publication. H-Coal data from HRI1982 publication
Gasoline
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MTG is Relatively Un-coupled TechnologyMTG is Relatively Un-coupled Technology
Products HC Yields
Gasoline ~89%
Fuel Gas ~1%
LPG ~10%
PRENFLOGasification
Hvy. Gasoline Treating
GasolineGasolineBlending
Heavy Gasoline
O2
LPGMethanol Synthesis
MTG Unit
CO-ShiftGas Treatment Fractionation
Feed Preparation
MTG Reactors
Coal / Biomass
Hydrogen
Main Advantage vs. Fischer-Tropsch: MTG is uncoupled from gas generation
(methanol storage tank)
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MTG has signifcantly less tailgas than FTMTG has signifcantly less tailgas than FT
Tail Gas is approx. 15 times less than in FTPRENFLO
Gasification
Hvy. Gasoline Treating
GasolineGasolineBlending
Heavy Gasoline
O2
LPGMethanol Synthesis
CO-ShiftGas Treatment FractionationMTG Reactors
Coal / Biomass
Hydrogen
Feed Preparation
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Not self-sufficient plant setupNot self-sufficient plant setup
• Maximisation of Liquid Yield (>20% higher than in FT)• Maximum carbon mitigation efficiency possible• Minimisation of other emissions
PRENFLOGasification
Hvy. Gasoline Treating
GasolineGasolineBlending
Heavy Gasoline
O2
LPGMethanol Synthesis
CO-ShiftGas Treatment FractionationMTG Reactors
Coal / Biomass
Hydrogen
Feed Preparation
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Self-sufficient plant setupSelf-sufficient plant setup
• Maximum flexibility to adjust to project specific requirements (power, carbon mitigation requirements etc.)
• High overall CTL efficiency
PRENFLOGasification
Hvy. Gasoline Treating
GasolineGasolineBlending
Heavy Gasoline
O2
LPGMethanol Synthesis
CO-ShiftGas Treatment FractionationMTG Reactors
Coal / Biomass
Hydrogen
Power / Steam Production
Feed Preparation
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Case Study: CTL based on MTGCase Study: CTL based on MTG
GasificationPRENFLO** CO-Shift
S Recovery
Sour Gas
MTG *Unit
AGRRectisol
Tail Gas
Raw Methanol
(max. 4% H2 O)
MethanolUnit
CO2
Sulfur
ASU N2 & CO2 Compression
Oxygen
Air
N2 & CO2 to consumers Gasoline
LPG
CO2 to Compression
CO2 from AGR
Coal
* MTG: ExxonMobil
** PRENFLO with Direct Quench (PDQ): Uhde
Appr. 2% CO2
• Lignite with high water and medium high ash content• Hard coal with a low water content and a medium high ash content
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Case Study: PRENFLO PDQ, Gasifier and Key FeaturesCase Study: PRENFLO PDQ, Gasifier and Key Features
pressurized entrained-flow gasification: 25-42 bar
dry coal dust feeding: with N2 or CO2 as transport gas
oxygen as gasification agent
temperature in gasifier: 1,350-1,600 °C (slaggingconditions)
4-6 side burners, tangential flow
Gasifier protected by membrane wall (steam) and slaglayer
Full water quench for syngas saturation
Simple and robust process concept
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Case Study: CTL based on MTG - ResultsCase Study: CTL based on MTG - ResultsItem Unit Lignite Hard Coal
Not self-suff. Self Suff. Self. Suff.
Coal Feed ar t/h 674 913 378
Coal Feed t. Gasif. t/h 425 570 353
Gasoline @92 R+0 bbl/d 18,000 18,000 18,000
LPG bbl/d 3,300 3,300 3,300
Thermal Efficiency
Overall CTL* % on HHV n.a. Base +5.4%
Specific CAPEX ** USD/bbl Base + 32.8% +26.6%
* Reported CTL efficiencies very strongly dependent on utility and upgrading assumptions, CO2 disposition assumptions, coal quality etc.
** Reported CAPEX figures vary strongly; comparability only given, if basis for CAPEX is transparant and comparable
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Summary and Key Project ConsiderationsSummary and Key Project Considerations
Market– Market forecast (e.g. EIA, IEA) demonstrate viability and necessity of CTL (and
BTL) for securing future liquids demand
Minimum Technical Risk– Methanol to Gasoline (MTG), PRENFLO Gasification and Methanol Synthesis are
commercially proven technologies
Simplicity– MTG does not require a “refinery” to make a marketable fuel product.
Operability and Availability– Methanol is storable which enhances operability between stages as well as plant
availability
Flexibility– MTG can be used for methanol from other sources.– CTL/MTG allows maximisation of liquids yield and CTL efficiency– MTG allows maximum flexibility in CTL plant set-up, taking into account project
specific considerations (such as power availaibility, carbon mitigation requirements etc.)
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• EMRE provides licenses for Methanol to Gasoline Technology
• EMRE provides basic engineering design package for licensees to perform detailed engineering design and construction.
• EMRE provides catalysts for the MTG process.
• EMRE provides assistance for start-up and troubleshooting.
• Uhde provides feasibility studies for the entire process of clean gasoline production from coal. The study includes gasification, gas treatment, methanol synthesis and MTG.
• Uhde provides licenses of different gasification technologies to meet customer’s specific need.
• Uhde also provides methanol synthesis technology.
• Uhde is a full range EPC contractor.
EMRE/Uhde Partnership Provides Full Range of CTL Services EMRE/Uhde Partnership Provides Full Range of CTL Services
Gasification Methanol
MTG
Coal
Gasoline
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Thanks!Thanks!
TransGas CTL (MTG) plant, Mingo County, WV, USA; employing 2 PRENFLO PDQ gasifiers and MTG for 18,000 bbl/d gasoline
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Slide Number 1Oil and Coal Reserves (Worldwide)Crude Oil Price DevelopmentPrice Developments Crude Oil vs. Natural Gas vs. CoalCoal to Liquids is moving forwardOptions for Coal To LiquidsUnique Shape Selective ChemistryMTG Was Commercially Operated2nd Generation MTG TechnologyJAM MTG Plant, Jincheng, ShanxiMTG Process Flow DiagramProduct and Process Simplicity for MTGMTG is Relatively Un-coupled TechnologyMTG has signifcantly less tailgas than FTNot self-sufficient plant setupSelf-sufficient plant setupCase Study: CTL based on MTGCase Study: PRENFLO PDQ, Gasifier and Key FeaturesCase Study: CTL based on MTG - ResultsSummary and Key Project ConsiderationsEMRE/Uhde Partnership Provides Full Range of CTL Services Slide Number 22