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An Alternative Route for Coal To Liquids (CTL) applying Methanol to Gasoline (MTG) technology An Alternative Route for Coal To Liquids (CTL) applying Methanol to Gasoline (MTG) technology Sam Tabak ExxonMobil Research & Engineering Stefan Hamel Max Heinritz-Adrian Adrian Brandl Uhde GmbH

An Alternative Route for Coal To Liquids (CTL)...COAL TO LIQUID Date Sources: FT Date Sasol 2004 publication. H-Coal data from HRI1982 publication Gasoline MTG is Relatively Un-coupled

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  • An Alternative Route for Coal To Liquids (CTL) applying Methanol to Gasoline (MTG) technology An Alternative Route for Coal To Liquids (CTL) applying Methanol to Gasoline (MTG) technology

    Sam Tabak

    ExxonMobil Research & Engineering

    Stefan HamelMax Heinritz-AdrianAdrian Brandl

    Uhde GmbH

  • Oil and Coal Reserves (Worldwide)Oil and Coal Reserves (Worldwide)

    • Proven oil reserves ~ 1,332 trillion barrels• Todays oil consumption ~ 85 million barrels / day⇒ proven oil reserves horizon at ~ 40 years

    • Proven coal reserves ~ 905 gigatons• Todays coal consumption ~ 5 gigatons / year⇒ proven coal reserves horizon at ~ 180 years

    ⇒ Coal will by far outlast crude oil

    ⇒ Difference increases under consideration of estimated resources

  • Crude Oil Price DevelopmentCrude Oil Price Development

    Crude Oil Prices recover from near-term decline in course of the world-wide financial and economic crises

    Crude Oil Price in Reference Case is projected to reach 130 USD/bbl (in 2007 dollars), respectively 189 USD/bbl (nominal dollars) in 2030

  • Price Developments Crude Oil vs. Natural Gas vs. CoalPrice Developments Crude Oil vs. Natural Gas vs. Coal

    ⇒ On the contrary: Coal prices remain stable below 3 USD / MMBTU⇒ Feasibility of Coal to Liquids will continuously increase

    Source: EIA Annual Energy Outlook, 2009, Early Release

    Energy Prices, 2007 dollars per MMBTU

  • Coal to Liquids is moving forwardCoal to Liquids is moving forward

    • Shenhua Coal to liquids (DL); started-up end 2008

    JAM Coal to liquids (MTG); start-up 1st half 2009

    Baard Energy ORCF Project; Wellsville, Ohio

    DKRW Energy CTL (MTG); Medicine Bow, Wy

    TGDS CTL (PDQ + MTG), Mingo County, WV

    • Further projects e.g. in India, Australia, South Africa etc.

    • Focus in Europe on BTL

    http://upload.wikimedia.org/wikipedia/commons/a/a4/Flag_of_the_United_States.svg

  • Liquid Fuels

    Options for Coal To LiquidsOptions for Coal To Liquids

    Gasification MeOH MTG

    Gasification F-T Refining

    Coal

    Gasification

    DirectLiquefaction Refining

    • All three routes: three step processes• Thermal efficiencies: essentially governed by the carbon hydrogen ratio of the feed

    and the fuel products.

  • Unique Shape Selective ChemistryUnique Shape Selective Chemistry

    Methanol

    Water

    Gasoline

    • Unique “Shape Selective” chemistry discovered in the early 1970’s

    • Development done through the 70’s/80’s on a variety of process options

    • Plant started up 1985 and operated successfully for ~10 years until conversion to chemical grade Methanol production

    • Second generation Coal based plant scheduled for mid 2009 start-up in China

    • Additional plant in Engineering for Medicine Bow, Wyoming

  • MTG Was Commercially OperatedMTG Was Commercially Operated

    Commercial 14500 BPD plant in New Plymouth New Zealand. Plant ownership 75% NZ Government and 25% ExxonMobil.

    MTG SynGas and MeOH Generation

  • 2nd Generation MTG Technology2nd Generation MTG Technology

    ExxonMobil is the world leader In catalyst development and we manufacture our own catalysts.

    • Second Generation Design based on learning's from 10 years of NZ operation

    • Improved heat integration• Improved process efficiency• Process re-optimized for coal-based

    methanol

    Reduced capital costReduced operating cost

  • JAM MTG Plant, Jincheng, ShanxiJAM MTG Plant, Jincheng, Shanxi

    2500 bbl/d plant as part of CTL demo plant; Start-up in 1st half 2009

    Picture courtesy of Shanxi Jincheng Anthracite Coal Mining Group

  • MTG Process Flow DiagramMTG Process Flow Diagram

    LPG

    Light Gasoline

    FinishedGasoline

    Treated GasolineHeavy

    Gasoline

    DME Reactor MTG Reactor(Multiple)

    BlendingBlending

    Compressor

    C2-

    Stabilized Gasoline

    LPG

    DeEthanizer Stabilizer StabilizerSplitter HGT Reactor

  • Product and Process Simplicity for MTGProduct and Process Simplicity for MTG

    DEWAX

    NaphthaReforming

    HDT/HDC

    Fischer Tropsch Fischer TropschCo Catalyst @220C Fe Catalyst@340C

    Fuel Gas 6 15 1.1LPG 6 23 10.0Naphtha 19 36 88.8 36.7Distillate 22 16 43.3Fuel Oil/Wax 46 5 20Oxygenates 1 5 0.1 0.34

    MTG H-Coal™ Direct Liquefaction

    HDT

    NaphthaReforming

    HDT/HDC

    NaphthaReforming

    HDT/HDC

    PolygasProcess

    Recovery

    REF

    INER

    YC

    OA

    L TO

    LIQ

    UID

    Date Sources: FT Date Sasol 2004 publication. H-Coal data from HRI1982 publication

    Gasoline

  • MTG is Relatively Un-coupled TechnologyMTG is Relatively Un-coupled Technology

    Products HC Yields

    Gasoline ~89%

    Fuel Gas ~1%

    LPG ~10%

    PRENFLOGasification

    Hvy. Gasoline Treating

    GasolineGasolineBlending

    Heavy Gasoline

    O2

    LPGMethanol Synthesis

    MTG Unit

    CO-ShiftGas Treatment Fractionation

    Feed Preparation

    MTG Reactors

    Coal / Biomass

    Hydrogen

    Main Advantage vs. Fischer-Tropsch: MTG is uncoupled from gas generation

    (methanol storage tank)

  • MTG has signifcantly less tailgas than FTMTG has signifcantly less tailgas than FT

    Tail Gas is approx. 15 times less than in FTPRENFLO

    Gasification

    Hvy. Gasoline Treating

    GasolineGasolineBlending

    Heavy Gasoline

    O2

    LPGMethanol Synthesis

    CO-ShiftGas Treatment FractionationMTG Reactors

    Coal / Biomass

    Hydrogen

    Feed Preparation

  • Not self-sufficient plant setupNot self-sufficient plant setup

    • Maximisation of Liquid Yield (>20% higher than in FT)• Maximum carbon mitigation efficiency possible• Minimisation of other emissions

    PRENFLOGasification

    Hvy. Gasoline Treating

    GasolineGasolineBlending

    Heavy Gasoline

    O2

    LPGMethanol Synthesis

    CO-ShiftGas Treatment FractionationMTG Reactors

    Coal / Biomass

    Hydrogen

    Feed Preparation

  • Self-sufficient plant setupSelf-sufficient plant setup

    • Maximum flexibility to adjust to project specific requirements (power, carbon mitigation requirements etc.)

    • High overall CTL efficiency

    PRENFLOGasification

    Hvy. Gasoline Treating

    GasolineGasolineBlending

    Heavy Gasoline

    O2

    LPGMethanol Synthesis

    CO-ShiftGas Treatment FractionationMTG Reactors

    Coal / Biomass

    Hydrogen

    Power / Steam Production

    Feed Preparation

  • Case Study: CTL based on MTGCase Study: CTL based on MTG

    GasificationPRENFLO** CO-Shift

    S Recovery

    Sour Gas

    MTG *Unit

    AGRRectisol

    Tail Gas

    Raw Methanol

    (max. 4% H2 O)

    MethanolUnit

    CO2

    Sulfur

    ASU N2 & CO2 Compression

    Oxygen

    Air

    N2 & CO2 to consumers Gasoline

    LPG

    CO2 to Compression

    CO2 from AGR

    Coal

    * MTG: ExxonMobil

    ** PRENFLO with Direct Quench (PDQ): Uhde

    Appr. 2% CO2

    • Lignite with high water and medium high ash content• Hard coal with a low water content and a medium high ash content

  • Case Study: PRENFLO PDQ, Gasifier and Key FeaturesCase Study: PRENFLO PDQ, Gasifier and Key Features

    pressurized entrained-flow gasification: 25-42 bar

    dry coal dust feeding: with N2 or CO2 as transport gas

    oxygen as gasification agent

    temperature in gasifier: 1,350-1,600 °C (slaggingconditions)

    4-6 side burners, tangential flow

    Gasifier protected by membrane wall (steam) and slaglayer

    Full water quench for syngas saturation

    Simple and robust process concept

  • Case Study: CTL based on MTG - ResultsCase Study: CTL based on MTG - ResultsItem Unit Lignite Hard Coal

    Not self-suff. Self Suff. Self. Suff.

    Coal Feed ar t/h 674 913 378

    Coal Feed t. Gasif. t/h 425 570 353

    Gasoline @92 R+0 bbl/d 18,000 18,000 18,000

    LPG bbl/d 3,300 3,300 3,300

    Thermal Efficiency

    Overall CTL* % on HHV n.a. Base +5.4%

    Specific CAPEX ** USD/bbl Base + 32.8% +26.6%

    * Reported CTL efficiencies very strongly dependent on utility and upgrading assumptions, CO2 disposition assumptions, coal quality etc.

    ** Reported CAPEX figures vary strongly; comparability only given, if basis for CAPEX is transparant and comparable

  • Summary and Key Project ConsiderationsSummary and Key Project Considerations

    Market– Market forecast (e.g. EIA, IEA) demonstrate viability and necessity of CTL (and

    BTL) for securing future liquids demand

    Minimum Technical Risk– Methanol to Gasoline (MTG), PRENFLO Gasification and Methanol Synthesis are

    commercially proven technologies

    Simplicity– MTG does not require a “refinery” to make a marketable fuel product.

    Operability and Availability– Methanol is storable which enhances operability between stages as well as plant

    availability

    Flexibility– MTG can be used for methanol from other sources.– CTL/MTG allows maximisation of liquids yield and CTL efficiency– MTG allows maximum flexibility in CTL plant set-up, taking into account project

    specific considerations (such as power availaibility, carbon mitigation requirements etc.)

  • • EMRE provides licenses for Methanol to Gasoline Technology

    • EMRE provides basic engineering design package for licensees to perform detailed engineering design and construction.

    • EMRE provides catalysts for the MTG process.

    • EMRE provides assistance for start-up and troubleshooting.

    • Uhde provides feasibility studies for the entire process of clean gasoline production from coal. The study includes gasification, gas treatment, methanol synthesis and MTG.

    • Uhde provides licenses of different gasification technologies to meet customer’s specific need.

    • Uhde also provides methanol synthesis technology.

    • Uhde is a full range EPC contractor.

    EMRE/Uhde Partnership Provides Full Range of CTL Services EMRE/Uhde Partnership Provides Full Range of CTL Services

    Gasification Methanol

    MTG

    Coal

    Gasoline

  • Thanks!Thanks!

    TransGas CTL (MTG) plant, Mingo County, WV, USA; employing 2 PRENFLO PDQ gasifiers and MTG for 18,000 bbl/d gasoline

    TheThe imagesimages containedcontained herein herein areare thethe propertyproperty of "of "TransGasTransGas DevelopmentDevelopment Systems, LLC" and Systems, LLC" and areare protectedprotected byby intellectualintellectual propertyproperty lawslaws of of thethe United United StatesStates and and otherother countriescountries

    Slide Number 1Oil and Coal Reserves (Worldwide)Crude Oil Price DevelopmentPrice Developments Crude Oil vs. Natural Gas vs. CoalCoal to Liquids is moving forwardOptions for Coal To LiquidsUnique Shape Selective ChemistryMTG Was Commercially Operated2nd Generation MTG TechnologyJAM MTG Plant, Jincheng, ShanxiMTG Process Flow DiagramProduct and Process Simplicity for MTGMTG is Relatively Un-coupled TechnologyMTG has signifcantly less tailgas than FTNot self-sufficient plant setupSelf-sufficient plant setupCase Study: CTL based on MTGCase Study: PRENFLO PDQ, Gasifier and Key FeaturesCase Study: CTL based on MTG - ResultsSummary and Key Project ConsiderationsEMRE/Uhde Partnership Provides Full Range of CTL Services Slide Number 22