Gasification Systems Overview Library/Events/2017/ucfe/5-17-0940... · Gasification Systems Program...

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Gasification Systems Program Overview

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Dave LyonsActing Technology Manager, Gasification

UCFERMay 17, 2017

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Fossil Energy – Coal Research Program GoalsDriving Down the Cost of Electricity of Coal Power with CCS

0% Reduction

20% Reduction

30% Reduction

40

50

60

70

80

90

100

110

State-of-the-Art 2025 Demo 2030 Demo

Goals are for greenfield plants. Costs include compression to 2,215 psia, but exclude CO2 transport and storage costs.

Cost of Electricity Reduction Targets

Transformational Technology

IGCC orSupercritical PC

2nd-Generation Technology

COE

Rela

tive

to T

oday

’s

Coal

with

Cap

ture

(%)

3

Challenges• Low natural gas prices • Lack of stringent Greenhouse Gas (GHG) control legislation:

Gasification based power is expected to compete well in a high-carbon capture future

Opportunities• High value products from coal via syngas production/conversion• Economic stability through diversified power sources• Set stage for significant GHG control across globe through

reduced cost of electricity with CCS

Gasification SystemsEconomic Challenges & Opportunities

POWERLIQUIDFUELS

FERTILIZERCHEMICALS

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Feed Systems• Oxygen separation• Expand fuel flexibility• Increase efficiency and reliability, and improve economicsGasifier Optimization and Plant Supporting Systems• Improve reliability• Increase efficiency and reliability, and improve economicsSyngas Processing Systems• Hydrogen and carbon dioxide separation• Control multi-contaminants to extremely low levels• Increase efficiency and reliability, and improve economics

Gasification Systems ProgramKey Technologies

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Gasification Systems Program

Coal

ParticulateRemoval

GasCleanup

ShiftReactor

Synthesis GasConversion Transportation Fuels

and Chemicals

Carbon Dioxide Utilization & Storage

Hydrogen

Gasifier

Generator

ElectricPower

ElectricPower

Heat RecoverySteam Generator

Steam

Steam Turbine

Stack

Steam

Combustor

Fuel Cells

GasTurbine

Air Separator

Oxygen

GaseousConstituents

Solids

HydrogenSeparation

Generator

FeedPump

SyngasCooler

90%

Compressed Air

Feed Systems

Syngas Processing

Gasifier Optimization

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Gasification Systems Program Projects

Oxygen

FEED SYSTEMSBench Scale

GTI O2 Production via ContactorRTI O2 Modular SystemsThermosolv O2 Modular SystemsUniv. S. CarolinaO2 Separation Fiber

MembranesTDA Air Separation SystemsAPCI Advanced Cryogenic Air

SeparationPraxair Hollow Fiber Air SeparationHiFunda ION-Electron Membrane

Pilot ScaleGTI Dry Coal Feed PumpPraxair Oxygen Transport Membrane

Feed Systems Key Technology:• Advanced air separation technologies are being

developed to • Significantly lower cost of oxygen production• Allow efficient integration of air separation

processes with gasification-based power and co-production plants.

• Fuel feed – innovative technology advancements to • Increase use of low-rank coals in dry feeding of

high-pressure gasifiers• Allow co-feeding of coal with biomass.

• Together, advancement in these technologies will have significant effect on reducing cost and increasing overall gasifier system efficiency

Bold: Current TRL of 2 or 3

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Program Strategy– Develop a lower cost oxygen separation system to reduce the cost of electricity

production as the current technology is energy intensiveBenefits

– In lab scale, hollow fiber sorbents have been shown to be 3 to 5 times more productive than traditional adsorbent contactors and additionally have the ability to perform efficient heat integration, enabling recovery of much of the energy required for gas cooling

Objective– To further investigate and test sub-ambient air separation process based on a rapidly

cycled pressure swing adsorption (RCPSA) system that use hollow fiber-sorbent contactors

Scope of Work– Fabricate hollow fiber contactors and generate sub-ambient isotherms for these

materials– Perform RCPSA experiments and assess the efficacy of an internal phase change

materialProject Team

– Praxair Inc., Georgia Institute of Technology Project Duration

– 10/15 - 12/17

Improving Energy Efficiency of Air Separation Via Hollow Fiber SorbentsPraxair

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Improving Energy Efficiency of Air Separation Via Hollow Fiber SorbentsPraxair

Low energy oxygen/nitrogen separation driven by sub-ambient adsorption based operation

A technology analysis plan (TAP) will be established for fiber sorbent-RCPSA system module performance:• Key parameters assessing the advanced fiber sorbent module performance

will be identifiedDetailed simulation studies of the fiber sorbent module at sub-ambient conditions will be done to establish a performance model in gPROMS:• Modeling will be done according to NETL guidelines on the input

parameters• Non-linear optimizers will then be coupled to the model to obtain trade-offs

of integrated fiber modules vs. ASU• Model results will be communicated using appropriate reporting guidelinesDetailed comparison between SOA and integrated ASU/fiber sorbent module case studies will be done• Benefits of the fiber sorbent RCPSA system will be quantified• Potential performance and cost goals will be quantifiedCost of electricity (COE) & net power plant efficiency (HHV & LHV) metrics of the integrated ASU/fiber sorbent module will be calculated and compared with SOA baselines

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SYNGAS PROCESSING SYSTEMSBench Scale

UK Chemical LoopingUW Catalytic GasificationVPI Catalytic GasificationTDA Small Particle Kinetic Benefits

Pilot ScaleRTI Warm Gas CleanupAlstom Chemical LoopingOSU Chemical Looping (x2)TDA Integrated CO2 Removal & WGS (x2)

CO2

H2 rich stream

Water Gas ShiftWater

Gas Shift

Syngas Processing Systems Key Technology:• Develop high-efficiency processes to

remove contaminants from raw syngas• Help reduce contaminants to

regulatory demanded limits• Remove potential contaminant

effects on downstream processes• Pursue various technologies for efficient

separation/recovery of hydrogen and carbon dioxide (CO2) from syngas

• Aid in carbon capture and storage initiatives

• Improve syngas utilization performance


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Program Strategy – Demonstrate new methods for improving the production and recovery of microbial

coal to methane conversion within unmineable fossil fuel resources Benefits

– There is commercial potential for using microbially enhanced methane recovery to boost methane production in current wells or to reactivate abandoned coalbed methane wells that already have infrastructure in place but are no longer producing methane actively

Objective– Develop new technology to demonstrate a new method for delivering microbes to

unmineable coal reservoirScope of Work

– Design a new ceramic proppant (used to "prop open" hydraulic fractures) specifically to have improved fluid transport properties while simultaneously delivering microbial consortia to coal seams

– Identify viable nutrients and microbial consortia for enhance methane production from coal

– Verify heating value, cost, and production rates of the nutrients and microbial consortia Project Team

– University of UtahProject Duration

– 10/14 - 9/17

Ceramic Proppant Design for In-Situ Microbially Enhanced MethaneRecoveryUniversity of Utah

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RIC: NETL’s Research and Innovation Center

GASIFIER OPTIMIZATION AND PLANT SUPPORTING SYSTEMS

Bench ScaleNETL/RIC Microbial Enhanced Coalbed

Systems (MECBM)NETL/RIC Process and Reaction

IntensificationNETL/RIC Virtual Reactor Design,

Validation, and OptimizationNETL/RIC Modular StudiesMontana St. Opt. of Microbial Activity (x2)Univ. of Utah Ceramic ProppantS. Illinois Univ. Optimized MicrobialPenn St. Univ. MECBM

Gasifier Optimization and Plant Supporting Systems Key Technology:• Improving the performance and reducing

the costs of advanced gasifiers• Better kinetic/particle models for

development of optimally configured gasifier

• New reactors for smaller applications• Increased efficiencies, better

economics• Coal bed methane microbe

conversion


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Advancing Coal Catalytic Gasification to Promote Optimum Syngas ProductionVirginia Polytechnic Institute & State University (VPI)

Program Strategy – Syngas production from catalytic coal gasification

Benefits– Improved use of fossil fuels, in particular low-rank coal, by using

suitable catalysts to advance gasification and create cleaner synthesis gas

Objective– Work involves experiments, kinetic modeling, and computational

fluid dynamics to advance catalytic gasification of coal and coal-biomass mixtures

Scope of Work– Characterization of the chemical kinetics and reaction mechanisms– Development of a set of models that can be integrated into MFIX,

OpenFOAM and other CFD modeling environmentsProject Team– VPI, University of Delaware, Northeastern University, Utah State

UniversityProject Duration 10/14 - 7/17

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• Microbial Enhanced Coalbed Systems (MECS) • Coal-to-Methane Characterization and Stimulation• Micro-Field Laboratory

• Process and Reaction Intensification • Microwave Reactions for Gasification• Non-Traditional Thermal Reactors• Enabling Materials and Manufacturing Technologies• Gasification Test Stand• Oxygen Carrier Development• Fischer-Tropsch Catalyst Development and Testing• CHP Reactor Design, Construction, and Testing• CTL Reactor Design, Construction, and Testing

• Virtual Reactor Design, Validation, and Optimization • Simulation-Based Optimization Toolset• CFD Application and Validation for Chemical Looping Devices• Biomass to Syngas Reactor Application and Validation

• Defining and Evaluating Modular Performance and Cost Metrics• Gasification Feasibility Study for 1 MWe Coal to Power• C&CBTL Feasibility Study for 1MWe Coal to Liquids• A 1 MWe Coal to Heat and Power Process with Improved Economics• A 1 MWe Coal to Liquids Process with Improved Economics

Modular Systems : NETL-RIC Research Areas

Dual E-Band Applicator

Standing Wave applicator

Advanced Reactor Simulation and Optimization Toolset

Advanced manufacturing enables non-traditional geometries

Questions?For more information, please contact:

Dave Lyons, Acting Gasification Technology [email protected]

mailto:[email protected]

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Extra Slides

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Energy Diversity and SecurityGasification can: Convert coal to power Convert coal to valuable products

(chemicals/fuels) Superior environmental performance,

including GHG Feasible for carbon capture

Recoverable Reserves at

Active Mines

477

Demonstrated Reserve

Base

Estimated Recoverable

Reserves 255

18.3

U.S. Coal Resourcesbillion short tons

Why the Interest in Coal Gasification?U.S. Has A Lot of Coal!

1,669

Identified Resources

3,906

TotalResources

https://www.eia.gov/energyexplained/index.cfm?page=coal_reserves

https://www.eia.gov/energyexplained/index.cfm?page=coal_reserves

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Benefits and Products of Gasification

Gasification can be• Used to make: hydrogen,

fertilizer, chemicals (methanol, plastics, etc.) and transportation fuels

• Lowest cost option to make power with almost total carbon dioxide (CO2) capture and storage

Gasification can play in the global market, including developing countries

WATER

COAL/PETCOKE

OXYGEN

BIOMASS

POWER

LIQUIDFUELS

FERTILIZER

CHEMICALSHYDROGEN

GAS CLEANUP/

GAS SEPARATION

CO2(for reuse/storage)

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UK Chemical LoopingUW Catalytic GasificationVPI Catalytic GasificationTDA Small Particle Kinetic Benefits

Pilot ScaleRTI Warm Gas CleanupAlstom Chemical LoopingOSU Chemical Looping (x2)TDA Integrated CO2 Removal & WGS (x2)

Oxygen

CO2

H2 rich stream

Water Gas Shift

RIC Microbial Enhanced Coalbed SystemsRIC Process and Reaction IntensificationRIC Virtual Reactor Design, Validation, and OptimizationRIC Modular Studies


GTI O2 Production via ContactorPraxair Hollow Fiber Air SeparationHiFunda Ion-Electron MembraneTDA Air Separation SystemsRTI O2 Modular SystemsThermosolv O2 Modular SystemsUSC O2 Separation Fiber MembranesAPCI Advanced Cryogenic Air Separation

Pilot ScaleGTI Dry Coal Feed PumpPraxair Oxygen Transport Membrane

Montana St Opt. of Microbial Activity (x2)U. of Utah Ceramic ProppantSIU Optimized MicrobialPSU MECBM

Water Gas Shift

Bench-scaleGASIFIER OPTIMIZATION AND PLANT SUPPORTING SYSTEMS


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Gasification Systems Program ProjectsCurrent TRL of 2 or 3



UK Chemical LoopingUW Catalytic GasificationVPI Catalytic Gasification

Pilot ScaleOSU Chemical LoopingTDA Warm Gas Multi-Contaminant

Removal System

Oxygen

CO2

H2 rich stream

Water Gas Shift

RIC Microbial Enhanced Coalbed SystemsRIC Process and Reaction IntensificationRIC Virtual Reactor Design, Validation, and OptimizationRIC Modular Studies


GTI O2 Production via ContactorPraxair Hollow Fiber Air SeparationHiFunda ION-Electron MembraneTDA Air Separation SystemsRTI O2 Modular SystemsThermosolv O2 Modular SystemsUSC O2 Separation Fiber

MembranesAPCI Advanced Cryogenic Air

Separation

Montana St Opt. of Microbial Activity (x2)U of Utah Ceramic ProppantSIU Optimized MicrobialPSU MECBM

Water Gas Shift

Bench-scaleGASIFIER OPTIMIZATION AND PLANT SUPPORTING SYSTEMS

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• Enable cost-competitive U.S. production of ultra-clean liquid transportation fuels (gasoline, diesel/jet fuel)

• At or below lifecycle greenhouse gas (GHG) emissions from conventional petroleum

• Either drop-in fuels or refinery feedstock• Combine fossil technologies with renewable

or other low carbon footprint technologies to reduce overall GHG emissions impact

• Novel hydrogen production technologies

DOE Vision for Coal and Coal-Biomass to Liquids

TECHNOLOGIES EXIST TO DO THIS NOW – except for costNEED TO DEVELOP LOWER COST AND MORE EFFICIENT TECHNOLOGIES

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Coal and Coal-Biomass to Liquids Technical Challenges and Opportunities

GaseousConstituents

Solids

Coal

ParticulateRemoval

GasCleanup

ShiftReactor

Synthesis GasConversion

Transportation Fuels and Chemicals


Hydrogen

Gasifier Steam

Air Separator

Oxygen

HydrogenSeparation

FeedPump

SyngasCooler

Compressed Air

Biomass

And Direct Coal Conversion Technologies

Challenges• Coal-biomass mixed feedstock chemical

kinetics/reactive properties• Processing/feeding coal-biomass mixtures

into the gasifier across a pressure gradient• Product characterization from gasifying coal-

biomass mixtures• High capital costs• Environmental concerns• Lower cost H2 donor systems/production

systems• Low value product production through

Fischer-Tropsch (FT) process• Heat management/catalyst life issues• Biomass contaminant impact on FT and

Water Gas Shift processes

Opportunities• Production of high value products (gasoline, jet

fuel, chemicals) from coal comparable to similar products from petroleum

• Economic stability through diversified transportation fuel sources

• Technology exports to countries with low domestic oil supplies, leading to more stable global oil prices

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• Coal-Biomass Feed and Gasification – Use of biomass mixed with coal to reduce the greenhouse gas (GHG) impact of traditional coal to liquids (CTL) approaches, technologies of interest include:

• Coal-biomass feed systems• Optimization of coal-biomass gasification, and use of resultant syngas

• Advanced Fuels Synthesis – Catalyst and reactor optimization for producing liquid hydrocarbon fuels from syngas resulting from gasification of coal-biomass mixtures, technologies of interest include:

• Advanced syngas processing through intensification/co-production/co-feeding in a Fischer-Tropsch plant to produce (primarily) diesel fuel

• Improvements to direct coal liquefaction (DCL) processes• Hybrid systems using a combination of DCL and syngas-based liquid fuel

production (may also include co-production/co-feeding systems)• GHG emission reduction technologies other than carbon capture and

storage or biomass co-feed

Coal and Coal-Biomass to Liquids ProgramKey Technologies

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Coal and Coal-Biomass to Liquids ProgramGasification-Based Technologies: Coal-Biomass Feed and Gasification, and Advanced Fuels Synthesis (syngas conversion into transportation fuel)

And Direct Coal Conversion Technologies (which don’t use gasification at all)KEY: Gray shaded areas are not

applicable to C&CBTL Program

GaseousConstituents

Solids

Coal

ParticulateRemoval

GasCleanup

ShiftReactor

Synthesis GasConversion

Transportation Fuels and Chemicals


Hydrogen

Gasifier Steam

Air Separator

Oxygen

HydrogenSeparation

FeedPump

SyngasCooler

Compressed Air

Biomass

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C&CBTL Program Projects

CO2

H2 rich stream

Water Gas Shift

COAL-BIOMASS FEED AND GASIFICATION

Princeton Synthetic Jet Fuel Production from Lignite/ Biomass w/ CO2 Capture

Battelle Direct CTL Jet Fuel from Biomass Derived Solvents

Water Gas Shift

Coal-Biomass Feed and Gasification Key Technology:• Advance scientific knowledge of the

feeding and conversion of biomass and coal-biomass mixtures as essential upstream steps for production of liquid transportation fuels with a lower net GHG emissions than conventional oil refining

• Handling and processing of coal/biomass mixtures

• Feed system compatibility• Downstream component impact• Conversion optimization

• Future work considerations could focus on modular energy systems

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Program Strategy• Develop a hybrid, direct coal-to-liquids (CTL) jet fuel process using novel biomass derived solvents to produce commercially viable jet

fuel cost competitive with petroleum, with equal or lower carbon footprintBenefits • High hydrogen-donor bio-oil solvents and two-stage catalytic syncrude hydrogenation/hydrotreating technologies to be advanced by

project development efforts• Eliminating molecular hydrogen required for producing syncrudeObjective• Demonstrate hybrid, direct CTL process for producing coal/bio-solvent syncrude and method for conversion of syncrude into jet fuel• Demonstrate straightforward path to near-term commercial production, significant reduction in capital and operating costs, and

substantial reduction in greenhouse gas emissions without carbon capture and storageScope of Work• Develop and refine major process steps at continuous bench scale, including: (1) biomass conversion to high hydrogen-donor solvents;

(2) coal dissolution in biomass-derived solvents to produce syncrude; and, (3) two-stage catalytic hydrogenation/ hydrotreating of syncrude to jet fuel and other distillates

• Scale-up to continuous, pre-pilot scale• Estimate process economics and greenhouse gas emissions reductionAccomplishments• Completed bench‐scale coal liquefaction testing and bench‐scale syncrude hydrogenation testing• Syncrude preparation underwayProject Team• Battelle Memorial Institute, Quantex, ARA, Intertek, PennState, UDRIProject Duration 10/14 – 6/17

Direct Coal to Liquid for Jet Fuel Using Biomass Derived SolventsBattelle Memorial Institute

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ADVANCED FUELS SYNTHESISBench Scale

RTI Hybrid CTL ProcessAltex GHG-reduced CBTL Jet Fuel ProcessCerametec GHG Reduction and Cost-Competitive

Mil-Spec Jet Fuel from CTLH-Quest Wave Liquefaction Mechanisms for

Coal/Biomass Jet Fuel ProductionSRI Indirect Liquefaction of Coal-Biomass for

Jet Fuel ProductionTDA Poison Resistant WGS Catalysts for

Biomass/Coal GasificationNETL/RIC FT Catalyst Development and TestingNETL/RIC Biomass to Syngas Reactor Application and

ValidationNETL/RIC Modular Studies

Pilot ScaleUK C&CBTL Gasification/Syngas Conversion

via FT

CO2

H2 rich stream

Water Gas ShiftWater

Gas Shift

Advanced Fuels Synthesis Key Technology:• Catalyst/reactor optimization

for producing liquid hydrocarbon fuels and valuable by-products from coal/coal-biomass mixtures

• Fuel synthesis product distribution

• Future work may include:• Direct coal conversion• Solid carbon product by-

products

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Program Strategy • Design, construct and operate coal/biomass-to-liquids (CBTL) facility at 1 bbl/day liquid fuels

capacity, provides developers affordable test bed for new “downstream” concepts and technologiesBenefits• CBTL technology enables production of valuable clean fuel and chemical products from domestic

coal while reducing CO2 emissions, enhancing U.S. energy security and independenceObjective• Compare compositions of Fischer-Tropsch (F-T) liquid fuels produced from coal-derived syngas

with mixture of coal and 8-15% biomass (torrefied basis) • Assess economics of CBTL process and compare cost of adding biomass to limit net CO2

emissions; investigate coal-torrefied biomass feed handling and preparation, (torrefaction releases water contained in biomass as well as superfluous volatiles making it more stable and easier to transport)

Scope of Work• Installation and shakedown of water-gas-shift, F-T synthesis, and hydrocracking• Commencement of initial integrated refinery runs (feed to gasification to separations and upgrading)• Continuous production runs of mini-refinery to produce quantities of liquid hydrocarbons • Analysis of technology and processes, including; scalability, cost, economics, product qualityProject Team• University of Kentucky Center for Applied Energy ResearchProject Duration • 10/12 – 9/17

Small Scale Pilot Plant for the Gasification of Coal and Coal/Biomass Blends andConversion of Derived Syngas to Liquid Fuels Via Fischer-Tropsch Synthesis University of Kentucky (UK) Center for Applied Energy Research (CAER)

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RTI Hybrid CTL ProcessAltex GHG-reduced CBTL Jet Fuel

ProcessCeramatec GHG Reduction and Cost-

Competitive Mil-Spec Jet Fuel from CTL

H-Quest Wave Liquefaction Mechanisms for Coal/Biomass Jet Fuel Production

SRI Indirect Liquefaction of Coal-Biomass for Jet Fuel Production

TDA Poison Resistant WGS Catalysts for Biomass/Coal Gasification

RIC FT Catalyst Development and TestingRIC Biomass to Syngas Reactor

Application and ValidationRIC Modular Studies

Pilot ScaleUK C&CBTL Gasification and Syngas

Conversion via FT

CO2

H2 rich stream

Water Gas Shift


Princeton Synthetic Jet Fuel Production from Lignite/Biomass w/ CO2 Capture


Water Gas Shift


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C&CBTL Program ProjectsCurrent TRL of 2 or 3



RTI Hybrid CTL ProcessAltex GHG-reduced CBTL Jet Fuel

ProcessCeramatec GHG Reduction and Cost-

Competitive Mil-Spec Jet Fuel from CTL

H-Quest Wave Liquefaction Mechanisms for Coal/Biomass Jet Fuel Production

SRI Indirect Liquefaction of Coal-Biomass for Jet Fuel Production

TDA Poison Resistant WGS Catalysts for Biomass/Coal Gasification

RIC FT Catalyst Development and TestingRIC Biomass to Syngas Reactor

Application and ValidationRIC Modular Studies

Pilot ScaleUK C&CBTL Gasification and Syngas

Conversion via FT

CO2

H2 rich stream

Water Gas Shift



Water Gas Shift

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