Transcript Slide 1

"Coal: Energy for the
21st Century and Beyond”
Gasification and BTU
Conversion of Coal
Martin Considine
Chris Hagedorn
Washington University Chemical Reaction
Engineering Laboratory (CREL)
“Energy: From Molecular Transformation to
Systems”
October 25, 2006
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Coal: Cornerstone to
America’s Energy Security
World Oil Reserves May Have Peaked
Growing Gas Demand Requires Unrealistic Imports
America is Short on Oil & Gas & Very Long on Coal
U.S. Coal is the Cornerstone to U.S. Energy Security
…For Advanced Power Generation
…For Substitute Fuels: Gasoline, Natural Gas & Hydrogen
…For the Reindustrialization of America
…For Environmental Improvements
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U.S. is Home to 27%
of World’s Coal Reserves
The Resource: 27% of the World’s Coal is in the United States
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Imbalance Forecast in
U.S. Gas Supply & Demand
26.9
20.9
30
25
21.1
21.0
22.0
18.2
30
25
20
20
15
15
10
10
5
5
0
0
U.S. Production (Trillion Cubic Feet)
U.S. Consumption (Trillion Cubic Feet)
Imports Unlikely to Close the Gap
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030
Source:
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Energy Information Administration, Annual Energy Review 2003, 1970-2000; Annual Energy Outlook 2006 Reference Case, 2005-2030.
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High Oil and Gas Prices Magnify
Coal’s Competitive Advantage
Electricity Generator Delivered Cost / MM Btu
$14
$12
Natural Gas Futures
$10
Natural Gas Deliveries
$8
$6
Coal Opportunity
Oil
$4
Coal Deliveries
$2
$0
1998
6
1999
2000
2001
2002
2003
2004
2005
2006
2007
Delivered cost of fossil fuel at steam electric utility plants.
Source: Platts Fossil-Fuel Receipts at Steam-Electric Utility Plants through June 2005. EIA November 2005 Short-Term
Energy Outlook, July – November 2005. NYMEX HH Futures December 2005 – December 2010, ino.com on Dec. 2, 2005.
2008
2009
2010
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NCC Sees Coal Converted to
Natural Gas, Other Energy Sources
 Study determined that clean coal technologies are
available to turn abundant U.S. coal into multiple
energy forms including electricity, natural gas,
transportation fuels and hydrogen
 By 2025, new capital investments of $515 billion
(present value of $350 billion) in Btu Conversion
technologies would create:
– 100 GW in new generation capacity
– 4 TCF of coal-to-natural-gas facilities
– 2.6 million barrels per day of coal-to-liquids
 U.S. coal production would more than double to 2.4
billion tons of coal per year
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Southern States Energy Board Sees Coal
Converted to Transportation Fuels
 SSEB calls for 5.6 million
barrels per day of oil from
U.S. coal
 Would require an additional 1
billion tons per year of
production
 Bipartisan council includes
governors and select
legislators from 16 states
and two territories
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Btu Conversion Technologies
Expand Markets for Coal
STEEL
ELECTRICITY
INDUSTRIAL GAS
PIPELINE
SYNGAS
SPECIALTY
CHEMICALS
ETHANOL
DIESEL
JET FUEL
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HYDROGEN
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What is Gasification ?
 Gasification is a controlled partial oxidation of fuels, such as
coal, to produce primarily carbon monoxide (CO) and hydrogen
(H2), called syngas; rather than complete combustion to carbon
dioxide (CO2) and water (H20).
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– Combustion:
(Cm Hn) + O2  CO2 + H20
– Gasification:
(Cm Hn) + 1/2 O2  CO + H2
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What Can You do with Syngas ?
 Combustion:
CO + H2 + O2  CO2 + H20
(for fuel)
 Water Gas Shift:
CO + H20 (steam)  CO2 + H2
(for hydrogen and CO2 recovery)
 Methanation:
CO + 3H2  CH4 + H20
(for SNG)
CO2 + 4H2  CH4 + 2H20
 Fischer-Tropsch:
nCO + 2nH2  (-CH2-)n + nH20
(for diesel and naphtha)
+ hydro-treating / refining
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Gasification for Btu Conversion to Gas or Liquids is
a Multi Step Chemical Processing Facility
Heat Exchanger
Coal-to-BTU Conversion
Process Elements
Gas
Cleanup
Pipeline-quality
Synthetic Natural Gas
or
Ultra-low Sulfur
Diesel / Jet Fuel
Methanation Process
Or
Steam
Air Separation Unit
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Fischer-Tropsch Process
In-plant use
of electricity
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Gasification Technology Differences
Moving Bed
Fluid Bed (Transport)
Entrained Bed
Process Description
Coal feed at top of gasifier
and moves down through
reactor by gravity. Steam
and oxygen fed through
bottom of gasifier.
Solid coal particles are
fluidized with syngas, and the
syngas and remaining solids
particles are separated.
Usually operates in a low
temperature (non-slagging)
Solid coal and syngas flow
together in an “entrained” bed.
Short residence time and high
operating temperature (slagging
mode). High carbon conversion
through use of high-purity oxygen
Technology Providers
Lurgi, EPIC
Southern/KBR
CoP, Shell, GE
Installed Capacity
18.7 GW th (42%)
0.9% GW th (2%)
25.4 GW th (56%)
Advantages
Low ranked coal
Low ranked coal
High reliability / proven
Low O2 demand
High purity syngas at high
pressure
Minimal bad byproducts
Low ranked coal (dry feed)
Disadvanteges
Tars and other bad by-
Low carbon conversion (high
products (additional
capex)
recycle)
High ranked coal (slurry feed)
Leachable slag
High O&M
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Coal’s Long-Term Markets
Expanding from Two to Five
Emerging Markets Include Gasification, Liquefaction & Hydrogen
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Details Regarding Potential
Gasification Project Types
Indicative BTU Conversion Project Characteristics
Industrial
Syngas
Synthetic
Natural Gas
Power
100,000 mcfd
600 MW
(units of output)
4,000 - 10,000
mcfd equivalent
40,000 - 80,000
bpd
Coal Usage
0.1 - 0.2
3
2
15
2–2½
5½-6
6–7
7-9
Project Size
IGCC
Fischer Tropsch
Liquids
(MMTPY)
Total Project
Lead Time
(Yrs)
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