Coal (and Biomass) to Liquid FuelsCoal (and Biomass) to Liquid Fuels James Katzer House Energy...

3/19/2009

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Coal (and Biomass) to Liquid Fuels

James KatzerHouse Energy Briefing

1310 Longworth House Office Bldg3:00, March 18, 2009

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U.S. Liquid Transport Fuels• 40% of our total primary energy consumption

comes form crude oil• 70% of total U.S. oil product consumption is in

transportation sector• U.S. consumes 13.7 million bbl of liquid

transportation fuels per day out of a total oil product consumption of 19.5 million bbl per day

• Over 90% of our transportation fuels come from d ilcrude oil

• 33 % of U.S. CO2eq emissions come from transportation sector

• U.S. transportation sector emissions are about 1.9 gigatonnes of CO2eq per year

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3/19/2009

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Crude Oil Refining Schematic

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Objectives• Costs, performance, and life-cycle GHG

emissions for key liquefaction processes for l d bi t li d di lcoal and biomass to gasoline and diesel,

without and with geologic CO2 storage in a uniform framework. Numbers are based on:– Consistent design basis and philosophy– One capital cost base– Same financial parameters & operating conditionsSame financial parameters & operating conditions– Fixed fuel costs (coal $42/ton; biomass $80/ton

dry)– Existing commercial technology

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Kreutz, T.G., E.D. Larson, G. Liu, and R.H. Williams. 2008. Fischer‐Tropsch Fuels from Coal and Biomass. In 25th Annual International Pittsburgh Coal Conference. Pittsburgh

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Options for Coal To LiquidsGasification F-T Refining

Gasification Liquefaction Refining

Gasification MeOH MTG

Coal

Water

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Liquid Fuels

• All are 3 Step Process• Thermal Efficiencies are Essentially Governed by C/H

ratios • Coal has a ratio of ~C/H ….All Fuels are ~C/H2• Coal ( which is CH) goes to Fuels (C/H2) plus CO2

+CO2

Comparison of Liquifaction ApproachesCompoundCompound

Low Temp FT*Low Temp FT*Co Catalyst Co Catalyst

@428F@428F

High Temp FT*High Temp FT*Fe CatalystFe Catalyst

@644F@644F

H CoalH CoalTM**TM**Direct Direct

LiquifactionLiquifactionMTG***MTG***

Methane 5 8 ? 0.7Ethylene 0 4 -Ethane 1 3 0 4

Requires Significant

Processing to Ethane 1 3 0.4Propylene 2 11 0.2Propane 1 2 4.3Butylenes 2 9 1.1Butane 1 1 10.9C5 – 160C 19 36 36.5 82.3

Distillate 22 16 43.2 -

Heavy Oil/Wax 46 5 20 -

gMake

Transportation Fuels

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Water Sol. Oxygenates 1 5 0.3 0.1Total 100 100 100 100

* Steyberg & Dry, “Fischer Tropsch Technology”, Elsevier, 2004 (All FT yields are prior to refining for gasoline octane ,and diesel pour point improvement)** H-Coal data from HRI1982 publication *** Final plant product with gasoline Octane 92 R+O

Liquid yield loss accompanies refining steps

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Coal to FT Fuels1 without CO2 Storage

HC

RecycleCompr.

unconverted syngas+ C1 - C4 FT gases

light ends

purge gas PowerIsland

net exportelectricity

ATRoxygen steam

flue gas

Air SeparUnit

ASU 17% of capital

Gasification& Quench

Grinding & Slurry Prep

oxygen

water

coal

SyngasScrubber

Acid GasRemoval

F-TRefining

F-TSynthesis

CO2

FlashRefrigeration

Plant

slag

Flash

methanol

CO2

syngas

Water GasShift

Regenerator

H2S + CO2To Claus/SCOT

C R

ecovery

finished gasoline & diesel blendstocks

raw FT product

Refinery H2 Prod

syncrude

gascooling

expander

Coal prep and Gasif30%

Syngas Clean-up including CO2 17%FT Synthesis with

recycle 13%

Refining 5%

Power Island 18%

Coal to Synthesis Gas Conversion, 64%

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Coal Feed, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio,Tonnes/day MW LHV % billion 07 $ $/SDB $/gge Cost, $/bbl FT/PD fuels

CTL‐RC‐V 24,300 427 49 4.9 97,600 1.50 56 2.18

1. 50,000 bbl/day total diesel plus gasoline

• With CO2 venting, CTL produces over twice the life-cycle GHG emissions.• The front end comprises 60 to 70 % of the total capital cost.

Coal to FT Fuels1 with CO2 Storage

HC

RecycleCompr.


light ends



ATRoxygen steam

flue gas



oxygen

water

coal

SyngasScrubber

Acid GasRemoval

F-TRefining

F-TSynthesis

CO2

FlashRefrigeration

Plant

slag

Flash

methanol

CO2

syngas

Water GasShift

150 bar CO2to pipeline

Regenerator


C R

ecovery


raw FT product

Refinery H2 Prod

syncrude

gascooling

expander

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Coal Feed, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio,Tonnes/day MW LHV % billion 07 $ $/SDB $/gge Cost, $/bbl FT/PD fuels

CTL‐RC‐V 24,300 427 49 4.9 97,600 1.50 56 2.18

CTL‐RC‐S 24,300 317 47.5 4.95 98,900 1.64 68 1.03

1. 50,000 bbl/d total diesel and gasoline

• With geologic CO2 storage, the life-cycle GHG emissions of CTL fuels can be equivalent to those of petroleum-derived fuels, and can be cost competitive

• Process design changes can reduce LC GHG emissions ratio to less than 1.0, but at a cost• Cost of CO2 avoided is only $11/tonne of CO2 because separation & capture are integral to the CTL process

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Coal Plus Biomass to FT Fuels

oxygencoal F-TRefining

F-TSynthesissyngas

HC

Recov

RecycleCompr.



raw FT product

syncrudelight ends



ATRoxygen steam

flue gas

FB Gasifier& Cyclone

Chopping & Lock hopper

oxygen

biomass TarCracking

steam

CO2



water

SyngasScrubber

Acid GasRemoval

CO2

FlashRefrigeration

Plant

slag

Flash

methanol

CO2

y g

Water GasShift

Regenerator


very

Refinery H2 Prodgas

coolingexpander

dry ash

gascooling

Filter

Coal Feed Biomass Feed Fuels TPC Spec. Cost Fuel Cost LC GHG Ratiotonnes/day tonnes/day bbl/day billion 07 $ $/SDB $/gge Alt/ PD fuels

91. Coal to biomass energy ratio = 57% / 43%, Illinois #6/switch grass

tonnes/day tonnes/day bbl/day billion 07 $ $/SDB $/gge Alt/ PD fuels

CBTL-RC-V1 2,750 3,580 10,000 1.32 132,000 2.31 0.90CBTL-RC-S1 2,750 3580 10,000 1.34 134,000 2.52 ‐0.02

• With V, CBTL can produce fuels with less GHG emissions than petroleum-derived fuels; with S, carbon-free fuels• Fuel cost higher for CBTL due to smaller scale plant and high biomass cost vs. CTL; CO2 avoided is $15/tonne• In CBTL, coal augments limited biomass supply and reduces cost

Breakeven Crude Oil Cost, at $0 CO2 Price

120

40

60

80

100

even

Cru

de O

il C

ost,

$/bb

l

10

0

20

1 2 3 4 5 6 7 8

Bre

ake

CTL-V CTL-S CBTL-V CBTL-S CTL-OT-V CTL-OT-S CBTL-OT-V CBTL-OT-S

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Breakeven Crude Oil Price at $50/tonne CO2eq Price

120

bl

40

60

80

100

ven

Cru

de O

il Pr

ice,

$/b

b

11

0

20

1 2 3 4 5 6 7 8

Bre

akev

CTL-V CTL-S CBTL-V CBTL-S CTL-OT-V CTL-OT-S CBTL-OT-V CBTL-OT-S

Effect of CO2 Price on Breakeven Crude Oil Cost

120

140

bl

40

60

80

100

120

akev

en C

rude

Oil

Pric

e, $

/bb

CTL-RC-VCTL-RC-S

12

0

20

0 10 20 30 40 50 60 70 80 90 100

Bre

a

Life-cycle Greenhouse Gas Price, $/tonne CO2eq

CTL-RC-SCBTL-RC-VCBTL-RC-S

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CTL Potential: Recyclewith CO2 Storage

• Produce liquid transportation fuels with life cycle CO emissions equivalent to thosecycle CO2eq emissions equivalent to those from petroleum-derived fuels

• Replace 2.25 million bbl/day of transport fuels in 15 yrs

• Net decarbonized power capacity, 15 GWe , equivalent to IGCC with CCSq

• Use 440 million tons/yr coal• $12/tonne CO2 avoided cost

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CTL Potential: Once-Through with CO2 Storage

• Produce liquid transportation fuels: – 2.5 million bbl/day liquid fuels with 25 % CO2 increase 2

over petroleum-derived fuels– 2.5 million bbl/day liquid fuels with emissions

comparable to petroleum-derived fuels, with 9% biomass added

– 2.5 million bbl/day liquid fuels, with ATR 10% lower LC GHG emissions ratio than petroleum-derived fuels (increased cost)

• Net decarbonized power capacity 73 GW ,Net decarbonized power capacity 73 GWe , equivalent to IGCC with CCS

• Use 600 million tons/yr coal• $18/tonne CO2 avoided cost

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CBTL Potential• Recycle (220 million tons/yr coal, 245 million tons/yr dry biomass)

– Vent CO22 0 illi bbl/d li id t t f l ith 90% f th CO• 2.0 million bbl/day liquid transport fuels with 90% of the CO2eq emissions of petroleum-derived fuels

• 19 GWe power generation capacity (IGCC emissions)– Store CO2

• 2.0 million bbl/day zero life-cycle GHG emission liquid transport fuels

• 15 GWe decarbonized power generation capacity (IGCC with CCS emissions)

• $15/tonne CO2 avoided costO Th h ith St• Once-Through with Storage (275 million tons of coal, same

biomass)• 1.6 million bbl/day zero life cycle GHG emission transport fuels• 55 GWe decarbonized power generation capacity (IGCC with CCS)• $21/tonne CO2 avoided cost

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Observations

• Geologic CO2 storage technology is key to viability of coal to liquids technologiesto viability of coal-to-liquids technologies

• Coal-to-fuels plants can produce competitive transport fuels with no increase in CO2eq emissions

• Coal-to-fuels plants can provide decarbonized electricity at 1/3 to 1/2 the CO2eq avoided cost of stand-alone power plants

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3/19/2009

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Observations – cont’d• Addition of less than 10% biomass to CTL

can reduce CO emissions of fuel tocan reduce CO2eq emissions of fuel to less than petroleum-derived fuels

• Increased biomass to ~ 40 energy % results in zero-carbon fuels and decarbonized electricity (IGCC-CCS) at somewhat higher cost, due to biomasssomewhat higher cost, due to biomass cost

• There is still no free lunch, all of this has impacts

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Thank You

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3/19/2009

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Proposed U.S. CTL Projects

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Fuel Costs for Different Routes3.5

1.5

2

2.5

3

Fuel Cost, $/gge

20

0

0.5

1

1 2 3 4 5 6 7 8CTL‐RC‐V CTL‐RC‐S CTG‐RC‐V CTG‐RC‐S BTL‐RC‐V BTL‐RC‐S CBTL‐RC‐V CBTL‐RC‐S

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Breakeven Crude Oil Cost, $0 CO2 Price

120

40

60

80

100

even

Cru

de O

il C

ost,

$/bb

l

21

0

20

1 2 3 4 5 6

Bre

ake

CTL-V CTL-S CBTL-V CBTL-S BTL-V BTL-S

Crude Oil Breakeven Cost for $50/tonne CO2eq Price

120

40

60

80

100

even

Cru

de O

il C

ost,

$/bb

l

22

0

20

1 2 3 4 5 6

Bre

ake

CTL-V CTL-S CBTL-V CBTL-S BTL-V BTL-S

3/19/2009

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Coal to Gasoline1 (MTG) with CO2 Storage

coal

RecycleCompr.

recycled syngas



flue gas

OxygenPlant

air

LPG + fuel gas



water

SyngasScrubber

Acid GasRemoval

MethanolRecovery

CO2

FlashRefrigerationPlant

slag

Flash

methanol

CO2

Water GasShift

150 bar CO2to pipeline

Regenerator


methanol(1.5% H2O)

MethanolSynthesis

gascooling

oxygenMTG

ReactorFinishedGasoline

water

Refining

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Coal Feed, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio,Tonnes/day MW LHV % billion 07 $ $/SDB $/gge Cost, $/bbl FT/PC fuels

CTL‐RC‐V 24,300 427 49 4.9 97,600 1.5 56 2.18CTL‐RC‐S 24,300 317 47.5 4.95 98,900 1.64 68 1.03

CTG‐RC‐S 21,100 156 53 4.02 80,400 1.54 51 1.17

1. 50,000 bbl/d total gasoline

• Methanol synthesis and MTG more selective, less expensive and require little refining• LPG sale rather than combustion for power reduces gasoline cost by about $0.20/gal

Direct Coal Liquefaction

C1 – C2

H2S, NH3, COx

Recycle H Gas Recovery

Coal Gasification orMethane Reforming

RefiningCoal Liquefactio

n

Hydro-treating

C1 C2Make-up Hydrogen

Coal + Catalyst

SlurryH-Donor

Recycle H2

Diesel FuelGasoline

LPGGas Recovery

Treatment

Power Gen.

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FractionationSlurry

De-AshedOil (DAO)

Heavy VacuumGas Oil (HVGO)

Ash RejectSolventDe-ashingPower, MW

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Life‐Cycle Greenhouse Gas Emissions

Gasoline

Diesel

CTL‐V,MTG

CTL‐MTG,CCS

BTL‐V,FT

BTL‐CCS,CCS

CBTL‐V,FT

CBTL‐CCS,FT

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‐20 ‐15 ‐10 ‐5 0 5 10 15 20 25

CTL‐V,FT

CTL‐CCS,FT

Life-Cycle Greenhouse Gas Emissions, kg CO2eq/gallon gasoline equivalent

lb/hr stpd bpsd MMBtu/hPlant InputCoal 1,550,621 18,607.5

Table II

Products Produced by a Direct Coal LiquefactionPlant Producing 50,000 bpsd of C5+ Products

Direct Coal Liquefaction Product Distribution

, , ,Fuel Gas 785

Liquid Products Naphtha 135,747 1,629 12,365 Light Distillate 61,096 733 4,943 Heavy Distillate 426,920 5,123 32,691Total Liquids 623,763 7,485 50,000

Lbs/bbl

Sulfur 22 631 272

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Sulfur 22,631 272 Ammonia 18,124 217 Phenol 2,137 25.6

Refuse (from Coal Cleaning)* 270,209 3,243Slag (from Gasification)* 175,877 2,111 *Moisture free basis

• 50,000 bbl/day liquid products• 14 to 20 Wt % of total hydrocarbon products are light gases

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Effect of CO2 Price on Breakeven Crude Oil Cost

120

140$/

bbl

20

40

60

80

100

Bre

akev

en C

rude

Oil

Pric

e, $

CTL-RC-V

CTL RC S

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0

20

0 10 20 30 40 50 60 70 80 90 100

B

Life-cycle Greenhouse Gas Price, $/tonne CO2eq

CTL-RC-S



oxygen

water

coal

SyngasScrubber

A id G

F-TRefining

F-TSynthesis

slagsyngas

Water GasShift

HC R

ecovery


unconverted syngas

raw FT product

Refinery H2 Prod

syn-crude

light ends

GTCCPowerIsland


gascooling

expander

CO

2

flue gas

Saturator

OxygenPlant N2 to gas turbine

N2

air

Coal to FT Fuels and Enhanced Power Production with CO2 Storage

water Acid GasRemoval

CO2

Flash

slag

Flash

CO2150 bar CO2to pipeline

Regenerator



2 Rem

oval

CO2 enriched methanol

methanolmethanol RefrigerationPlant

Coal Feed, Fuels, Net Power, Effic, TPC, Spec. Cost Fuel Cost, Br'evn Crude LC GHG Ratio,Tonnes/day bbl/day MW LHV % billion 07 $ $/SDB $/gge Cost, $/bbl FT/PC fuels

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CTL‐RC‐V 24,300 50,000 427 49 4.9 97,600 1.5 56 2.18CTL‐RC‐S 24,300 50,000 317 47.5 4.95 98,900 1.64 68 1.03CTG‐RC‐S 21,100 50,000 156 53 4.02 80,400 1.54 51 1.17

CTL‐OT‐S 33,100 50,000 1466 46.5 6.02 120,400 1.39 51 1.28

• Once through reduces cost in synthesis loop but has bigger power plant and more coal processing• Power system expansion uses FT heat and comes at lower marginal cost than IGCC plant cost• LC GHG Ratio could be reduced if a reformer and/or shift and additional CO2 removal added• CO2 avoided cost is $18/tonne

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Effect of Life-Cycle GHG Price on Breakeven Crude Oil Cost

140

160

bl

40

60

80

100

120

akev

en C

rude

Oil

Cos

t, $/

bb

CBTL-RC-S CTL-RC-S

29

0

20

0 10 20 30 40 50 60 70 80 90 100

Bre

a

Life-Cycle Greenhouse Gas Price, $/tonne CO2eq

CTL-OT-S CBTL-OT-S

CBTL-OT-V CTL-OT-V

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Coal (and Biomass) to Liquid FuelsCoal (and Biomass) to Liquid Fuels James Katzer House Energy...

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