Abstract Process Economics Program Report 271 COAL TO GASOLINE (December 2009)

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1 Abstract Process Economics Program Report 271 COAL TO GASOLINE (December 2009) Rising world oil prices have renewed interest in producing fuel from unconventional sources such as coal, oil shale, and biomass. Large coal reserves and viable technology to produce liquid fuels from coal give promise to the rebirth of a U.S. domestic coal industry. In the long term it makes sense to rigorously pursue the commercial development of coal to liquids (CTL) technologies from the perspective that it may be the only pathway that can deal with the tyranny of large numbers required to close the gap between supply and demand for transportation fuels. The United States has many opportunities including improving energy efficiencies that alone however will not be sufficient. Fiscal and regulatory actions will also be needed to promote greater economic and energy security. CTL must be an important part of the solution portfolio as the nation needs to respond to the realities of world energy markets, including global energy demand and the need to protect the environment. A commercially competitive CTL industry in a high energy price environment could be producing as much as 3 million barrels per day of high quality liquid fuels by This level of fuels production would provide about 15% of the current oil demand in the U.S. and would provide the means required to break the current national addiction to oil. In this report we examine the technologies involved to produce fuels from coal by two of the most promising routes, including high temperature Fischer-Tropsch (F-T) and methanol to gasoline (MTG. The first F-T route produces a slate of transportation fuels including gasoline, jet fuel, diesel, and fuel oil. The second route produces a 90+% yield of gasoline from methanol, which can be produced either from coal or natural gas. Finally, this report provides a combination of simulated and conceptual designs and economic analysis for the production of F-T liquids using high temperature synthesis technology. The bases for this analysis includes the construction of both demonstration and refinery scale plants that are free-standing. SRI Consulting PEP Report 271

3 SRIC agrees to assign professionally qualified personnel to the preparation of the Process Economics Program s reports and will perform the work in conformance with generally accepted professional standards. No other warranties expressed or implied are made. Because the reports are of an advisory nature, neither SRIC nor its employees will assume any liability for the special or consequential damages arising from the Client s use of the results contained in the reports. The Client agrees to indemnify, defend, and hold SRIC, its officers, and employees harmless from any liability to any third party resulting directly or indirectly from the Client s use of the reports or other deliverables produced by SRIC pursuant to this agreement For detailed marketing data and information, the reader is referred to one of the SRI Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

4 CONTENTS 1 INTRODUCTION BACKGROUND Coal to Liquids CTL Commercialization Risks CO 2 Storage Indirect Liquefaction Technologies Biomass Gasification CTL Synthesis Fischer-Tropsch Synthesis Methanol to Gasoline Emerging Innovative CTL Technologies Methane Oxidation to Methanol The PWR Compact Gasifier Co-fed Coal/Biomass to Liquids (CBTL) Prospective Carbon Policy Impacts on F-T Liquids Projects Microchannel Technology for F-T Synthesis Bio-butanol Chemical Looping Hybrid Technologies Direct Coal Liquefaction Commercializing F-T CTL for Fuels Production Only OVERVIEW Feedstock Gasification Fischer-Tropsch Synthesis Product Upgrading (Syncrude Refining) Fuels Specifications SRI Consulting iii PEP Report 271

5 CONTENTS (Continued) Gasoline International Gasoline Specifications Motor Gasoline Properties Octane Number Volatility Density Oxygenate Content Olefin Content Aromatics Content Sulfur Content Metal Content Oxidation Stability and Gum Formation Future Motor Gasoline Specifications Aviation Turbine Fuel (Jet Fuel) International Specifications Aviation Turbine Fuel Properties Heat of Combustion Density and Viscosity Aromatic Content and Smoke Point Sulfur Content Freezing Point Volatility Thermal Stability Future Aviation Turbine Fuel Specifications Diesel Fuel International Diesel Specifications Diesel Properties Cetane Number Flash Point Density and Viscosity Aromatic Content Sulfur Content SRI Consulting iv PEP Report 271

6 CONTENTS (Continued) Lubricity Cold Flow Properties Future Diesel SUMMARY MARKETS TECHNOLOGY ECONOMICS COST ESTIMATES Fixed Capital Costs Production Costs Profitability Discussion INDUSTRY STATUS INTRODUCTION POTENTIAL CTL DEVELOPMENT BENEFITS National Security Benefits Oil Supply Disruption Benefits ENVIRONMENTAL IMPACTS OF COAL TO LIQUIDS PRODUCTION Greenhouse Gas Emissions Air Quality Land Use, Ecological and Water Quality Impacts Coal Mining Impacts Water Requirements INCENTIVES TO ENCOURAGE PRIVATE INVESTMENT FULL SCALE CTL PRODUCTION Technical Viability and Commercial Readiness Timeline for CTL Development SRI Consulting v PEP Report 271

7 CONTENTS (Continued) 4 TECHNOLOGY REVIEW DIRECT COAL LIQUEFACTION INDIRECT COAL LIQUEFACTION Methanol as a Synthetic Fuel for Transportation Dimethyl Ether (DME) As A Synthetic Fuel FT Synthesis Methanol to Gasoline Long Term Environmental Considerations SYNGAS FROM COAL GASIFICATION GASIFICATION PROCESS CHEMISTRY REVIEW OF PROCESS Gasification Pressure Gasifier Fuel Heat Recovery Systems Comparative Features of the Shell and GE Gasifiers PROCESS DESCRIPTION Fuel Feed System Extent of CO 2 Removal Carbonyl Hydrolysis Shift Converter Mercury Removal Acid Gas Removal Sulfur Recovery and Tail Gas Treating BASIS FOR ESTIMATES AND EVALUATION Section Coal Receiving and Storage Section Air Separation Plant Section Coal Preparation and Gasification SRI Consulting vi PEP Report 271

8 CONTENTS (Continued) Section Shift, Cooling and Mercury Removal Section CO 2 Removal and AGR Section Claus/SCOT Claus Sub-Section SCOT Sub-Section COST ESTIMATES HIGH TEMPERATURE FISCHER-TROPSCH SYNTHESIS PROCESS CHEMISTRY CATALYST HIGH-TEMPERATURE REACTORS Operating Conditions FISCHER TROPSCH GAS LOOP Synthesis Gas Composition Fischer-Tropsch Technology Selection and Process Requirements Environmental Aspects Open vs. Closed Loops H 2 /CO ratio and CO Content Methane Content Coal Tar Content Gas Loop Configurations BASES & ASSUMPTIONS FOR PROCESS DESIGN & COST ESTIMATION PROCESS DESCRIPTION Section 700 Fischer-Tropsch Synthesis Cryogenic Requirements of F-T Section Waste Heat Recovery in F-T Section PROCESS DISCUSSION Catalyst & Product Composition SRI Consulting vii PEP Report 271

9 CONTENTS (Continued) Overall Fuel Conversion Efficiency Wastewater Discharge Main Streams Flow Rates CO 2 Absorption & Syngas Drying Materials of Construction F-T PRODUCTS UPGRADING (SECTION 800) ALKYLATION OLIGOMERIZATION C 3 Oligomerization C 4 Oligomerization ISOMERIZATION Olefin Saturation Section Isomerization Section AROMATIZATION Reforming Section Aromatic Separation Section COST ESTIMATES Fixed-Capital Costs Production Costs SYNCRUDE REFINING INTRODUCTION Components of Syncrude Paraffins Mono-olefins Aromatics Oxygenates Alcohols SRI Consulting viii PEP Report 271

10 CONTENTS (Continued) Aldehydes Carboxylic Acids Esters Ketones Metal Containing Compounds α-values of Commercial Syncrudes Comparison of Crude Oil and Syncrude Conceptual F-T Refinery Designs Process Simulation Packages Custom Software Spreadsheets Potential F-T Refining Technologies Olefin Conversion Double Bond Isomerization Oligomerization Acidic Resin Zeolite Amorphous Silica-alumina (ASA) Solid Phosphoric Acid (SPA) Homogeneous Catalysts Olefin Skeletal Isomerization Pentene Skeletal Isomerization Etherification Aliphatic Alkylation Aromatic Alkylation Hydrogen Addition Hydrotreating Hydroisomerization C 4 Isomerization C 5 /C 6 Isomerization C 7 Isomerization Hydrocracking SRI Consulting ix PEP Report 271

11 CONTENTS (Continued) Hydrogen Rejection Catalytic Reforming Pt/Al 2 O 3 based Bifunctional Catalysts Pt/L-Zeolite Reforming Aromatization Alcohol Dehydration Environmental Friendliness and Maximum Gasoline Production Achieving Octane Number for HTFT Gasoline Paraffins Aromatics HTFT Olefinic Gasoline HTFT Oxygenated Gasoline Jet Fuel Refining Diesel Fuel Refining R&D Needs Separation and Properties Oxygenate Refining Catalysis of Linear α- Olefin and 1-Alcohol Conversions Metal Carboxylates Feedstock Integration HTFT MOTOR GASOLINE REFINERY Distillate and Residue Fractions HTFT Hydrotreating Diesel Lubricity HTFT Residue Hydrocracking Combined Hydrotreating and Hydrocracking Combined Hydroisomerization and Hydrocracking General Selection of HTFT Process Catalysts Recovery of Oxygenates from Fischer-Tropsch Aqueous Product Chemicals Recovery SRI Consulting x PEP Report 271

12 CONTENTS (Concluded) Primary Separation Column Carbonyl Recovery Alcohols Recovery Alcohol Dehydration Oxygenate Conversion by Acid Catalysts Benzene and Aromatic Alkylation Alkylation of F-T Syncrude Oligomerization Combined with Alkylation Hydrogenation of Olefins Oligomerization of F-T olefins SPA Oligomerization Pentene Hydroisomerization INTEGRATED PRODUCTION OF GASOLINE FROM COAL PROCESS ECONOMICS DESIGN BASES COST ESTIMATES Fixed Capital Costs Production Costs Economics & Profitability Discussion APPENDIX A: PATENT SUMMARY TABLES... A-1 APPENDIX B: DESIGN AND COST BASES... B-1 APPENDIX C: CITED REFERENCES... C-1 APPENDIX D: PATENT REFERENCES BY COMPANY... D-1 APPENDIX E: PROCESS FLOW DIAGRAM... E-1 SRI Consulting xi PEP Report 271

13 ILLUSTRATIONS 1.1 Indirect Coal Liquefaction Process Steps Product Value of F-T Fuels Product as a Function of After-Tax ROI Production Costs Breakdown Direct Coal Liquefaction Sasol Advanced Synthol Reactor Sasol Reactor Product Slates Shell SCGP Gasification Process Motor-Gasoline from Coal by High-Temperature Fluidized Bed F-T Tech Process Flow Diagram... E Raw and Clean Syngas Compositions Coal Gasification of Syngas Feed to Fischer Tropsch... E Product Yields from Fischer-Tropsch Synthesis Product Upgrading Block Flow Diagram Steam Flow Circuit (F-T Section) Process Flow Diagram... E HTFT Distillate and Residue Refining Generic Process Flow Schematic Alternative Combined Hydrotreating/Hydroisomerization Process Flow Schematics Generalized Design for Defining Important Catalysts for Upgrading Fischer Tropsch Syncrude to Fuel Simplified Block Flow Diagram for Chemicals Recovery from Reaction Water Primary Product Separation for Refining Fischer-Tropsch Aqueous Products Carbonyls Recovery Process Flow Schematic Alcohols Recovery Process Flow Schematic Fischer-Tropsch Aqueous Phase Refining by Catalytic Alcohol Dehydration Solid Phosphoric Acid Catalyzed Combined Oligomerization and Alkylation Process to Produce Jet Fuel Recycle (Tetramer Mode) Operation for Refinery Scale Distillate Production by Oligomerization of Fischer Tropsch Olefins Over SPA SRI Consulting xii PEP Report 271

14 ILLUSTRATIONS (Concluded) 7.11 Separate Processing (Split Mode) Operation for Refinery Scale Distillate Production by Oligomerization of Fischer-Tropsch Olefins over SPA Process for Conversion of C5/C6 Fischer-Tropsch Naphtha to Isomerate over Pt- Mordenite Catalyst Product Value of F-T Fuels Product as a Function of After-Tax ROI Production Costs Breakdown SRI Consulting xiii PEP Report 271

15 TABLES 1.1 Effect of Reaction Temperature on Iron Catalyzed Fischer-Tropsch Synthesis Comparative Reaction Product Slates of Fischer-Tropsch with MTG DOE Illinois #6 Coal Composition (Wet, Ash Free) Comparative Features of Dry and Slurry Feed Gasifiers (Shell and GE) Design Specification for Gas Clean Up Systems Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Stream Flows Process Section Basis for Estimates and Evaluations Design Basis for Coal to Gasoline Process Syngas Composition Specifications Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Design Bases Processing of F-T Syncrude Fractions Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Stream Flows Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Utilities Summary Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Total Capital Investment Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Production Costs Motor-Gasoline from Coal by High-Temperature Fixed Fluidized Bed F-T Tech Major Equipment Octane Numbers for Some Linear Olefins Blending Vapor Pressures and Blending Octane Number of Fuel Alcohols and Ethers Compatibility of Refining Technologies with Fischer-Tropsch Syncrude and Their Overall Environmental Friendliness Comparison of Straight Run Iron Based HTFT Naphtha to Specifications and Quality Requirements of Euro Compound Physical Properties Relevant to Jet Fuel Requirements SRI Consulting xiv PEP Report 271

16 TABLES (Concluded) 7.6 Selective Properties of SRAGO HTFT vs. Mixed Arabian Crude Standard Heats of Reaction for Some Common HTFT Distillate Hydrotreating Reaction Hydrotreated Distillate Hydrocracking HTFT Vacuum Gas Oil to Middle Distillate Oxygenates in the Aqueous Product of Synthol HTFT Synthesis Motor-Gasoline from Coal by High-Temperature Fluidized Bed F-T Tech Main Design Bases Motor-Gasoline from Coal by High-Temperature Fluidized Bed F-T Tech Total Capital Investment Motor-Gasoline from Coal by High-Temperature Fluidized Bed F-T Tech Production Costs Motor-Gasoline from Coal by High-Temperature Fluidized Bed F-T Tech Production Costs Motor-Gasoline from Coal by High-Temperature Fluidized Bed F-T Tech Utilities Summary SRI Consulting xv PEP Report 271

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