3/19/2009
1
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.
unconverted syngas+ C1 - C4 FT gases
light ends
purge gas PowerIsland
net exportelectricity
ATRoxygen steam
flue gas
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
150 bar CO2to pipeline
Regenerator
H2S + CO2To Claus/SCOT
C R
ecovery
finished gasoline & diesel blendstocks
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.
finished gasoline & diesel blendstocks
unconverted syngas+ C1 - C4 FT gases
raw FT product
syncrudelight ends
purge gas PowerIsland
net exportelectricity
ATRoxygen steam
flue gas
FB Gasifier& Cyclone
Chopping & Lock hopper
oxygen
biomass TarCracking
steam
CO2
Gasification& Quench
Grinding & Slurry Prep
water
SyngasScrubber
Acid GasRemoval
CO2
FlashRefrigeration
Plant
slag
Flash
methanol
CO2
y g
Water GasShift
Regenerator
H2S + CO2To Claus/SCOT
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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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
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Coal to Gasoline1 (MTG) with CO2 Storage
coal
RecycleCompr.
recycled syngas
purge gas PowerIsland
net exportelectricity
flue gas
OxygenPlant
air
LPG + fuel gas
Gasification& Quench
Grinding & Slurry Prep
water
SyngasScrubber
Acid GasRemoval
MethanolRecovery
CO2
FlashRefrigerationPlant
slag
Flash
methanol
CO2
Water GasShift
150 bar CO2to pipeline
Regenerator
H2S + CO2To Claus/SCOT
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
27
0
20
0 10 20 30 40 50 60 70 80 90 100
B
Life-cycle Greenhouse Gas Price, $/tonne CO2eq
CTL-RC-S
Gasification& Quench
Grinding & Slurry Prep
oxygen
water
coal
SyngasScrubber
A id G
F-TRefining
F-TSynthesis
slagsyngas
Water GasShift
HC R
ecovery
finished gasoline & diesel blendstocks
unconverted syngas
raw FT product
Refinery H2 Prod
syn-crude
light ends
GTCCPowerIsland
net exportelectricity
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
H2S + CO2To Claus/SCOT
unconverted syngas+ C1 - C4 FT gases
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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