Coal to Liquid

Sept 2011

Excellence Through Insight

Confidential & Proprietary

Coal Liquefaction
Coal can be converted to liquid fuels either by removal of carbon or addition of hydrogen The first approach is know as carbonization, and the second is know as liquefaction The major objective of coal liquefaction is to produce synthetics oil to supplement the natural sources of petroleum.

Confidential & Proprietary

WHY CTL ?

Confidential & Proprietary

Advantages of Coal To Liquid(CTL) Fuels

CTL Improves national and economic security Lessens dependence on foreign oil Provides environmental benefits
Cleaner fuels that reduce NOx and particulate emissions Enables use of higher efficiency engines Is capable of capturing CO2 emissions Provides geographic diversity as energy source

Confidential & Proprietary

Coal Liquefaction
Very expensive Liquefaction attractive for transportation fuel Indirect liquefaction commercially proven (>50 yrs) Acid gas removal by amines (CO2, H2S) S removal by Claus Process H2S + O2 = H2O + SO2 H2S + SO2 = S + H2O

Confidential & Proprietary

Two Basic Approaches To Convert Coal To A Liquid Fuel

1. Direct Liquefaction: Dissolves coal in a solvent at elevated temperature and pressure Combined with hydrogen gas and a catalyst 2. Indirect Liquefaction: Involves first gasifying coal, followed by reacting carbon monoxide and hydrogen together nCO + (2n+1)H2 = CnH2n+2 + nH2O

Confidential & Proprietary

Comparison of Processes
DIRECT LIQUEFACTION

INDIRECT LIQUEFACTION
Complete breakdown of coal with steam and oxygen Sulfur is removed from the syngas Syngas reacted over catalyst at 300 C and 30 bars Produces a lighter suite of products; high quality gasoline and petrochemicals Oxygenated chemicals

Adds hydrogen to break down the coal Dissolves in a solvent followed by hydrocracking Operates at 450 C and 170 bars Light products are distilled Medium and heavy distillates obtained from vacuum distillation Liquid yields of 70% of the dry weight of coal feed

Confidential & Proprietary

SASOL in South Africa

Indirect Coal liquefaction is proven technology

South Africas SASOL Co. developed a commercial coal liquids industry (fuel plus chemicals)
Confidential & Proprietary

What is Gasification

Confidential & Proprietary

Generic Coal Gasification Reactor

Confidential & Proprietary

10

Gasifier types & Design Configurations

Confidential & Proprietary

11

Different type of Gasification Process

Confidential & Proprietary

12

Process Flow Chart for CTL

Coal

Gasification

Gas Treating

Hydrogen Recovery

H2

Ash Disposal

Sulfur Recovery
LPG

F-T Synthesis

Product Refining

Naphtha

Gasoline Diesel

Confidential & Proprietary

13

Confidential & Proprietary

14

Acid Gas Removal (Rectisol)

Rectisol process for the removal of CO, H2S, Carbonly sulfide, organic sulfur compound, HCN and condensable HC from the cooled raw prodect gas

Confidential & Proprietary

15

Confidential & Proprietary

16

Gas Liquor separation

Gas liquor produced in cool down of RG GL contain dissolved gases such as crude gas components, NH3, Hydrocyanic acid, Tar, oil, phenols, chlorine, fluorine, fatty acids etc Gaseous components are separated by flashing to atm pressure. The liq and sold components are separated by gravity separation. GL fed to this unit is cooled & depressurized using control valves and a specially designed expansion drum. The released gases are routed to the Sulfur Recovery unit for H2S removal

Confidential & Proprietary

17

GL Separation

Confidential & Proprietary

18

Phenosolvan Process
Phenosolvan process consist of Two main units : 16side
Filtration Extraction Solvent recovery

17side
Deacidifer Total Stipper Ammonia Fractionators

Confidential & Proprietary

19

Confidential & Proprietary

20

Total Stripper (X17VL-X04)

Confidential & Proprietary

21

Introduction

Confidential & Proprietary

22

(I) Normal Operation :

Confidential & Proprietary

23

Thank You !!!

Confidential & Proprietary

24

Direct Liquefaction of Coal Attractive Because of

Low

transportation cost Less chemical transformation required Higher efficiency than high Btu gas production Easy to store Less water required for manufacture However, processing slurries at high temperature and pressure presents difficulties with equipment life and solid/liquid separation (still not commercial)
Confidential & Proprietary

25

Gasifier Type

Confidential & Proprietary

26

Fischer Tropsch synthesis

The purified synthesis gas leaving from Rectisol unit undergoes FT synthesis whereby hydrocarbons are produced by catalytic conversion of CO and H2 The FT process can be used to produce either light synthetic crude(syncrude) oil and light olefins or heavy HC Syncrude can be refined to gasoline and diesel Heavy HC to special wax or, if hyrocracked and/or isomerizes, to produce diesel fuel, lube oils and Nephtha

Confidential & Proprietary

27

FT Synthesis
FT synthesis can be generalized by the following chemical reation

Confidential & Proprietary

28

FT Synthesis

Confidential & Proprietary

29

FT Process

Confidential & Proprietary

30

Methanol Synthesis

Synthesis of Methanol from Syngas Synthesis of Dimethylether (DME) from Methanol Synthesis of DME directly from Syngas

Confidential & Proprietary

31

Synthesis of Methanol

Confidential & Proprietary

32

Synthesis gas preparation

Feed gas introduced to Methanol synthesis loop must contain the correct proportions of CO, CO2 and H2 Synthesis gas composition adjusted by shift reaction and steam reforming RG from purification section contains methane which is unwanted component in synthesis feed The methane and other light HC produced are split into H2 and CO by steam Reforming

Confidential & Proprietary

33

Operating condition of Methanol

Confidential & Proprietary

34

Confidential & Proprietary

35