Coal-to-Liquid via Gasel® and H-Coal® Bharat Goenka
Jan 03, 2016
Coal-to-Liquid via Gasel® and H-Coal®
Bharat Goenka
1
• Axens in brief
• Opportunities for Coal to Liquids
• Processes for Coal Liquefaction (Direct/Indirect)
• Guidelines for a choice & Economical data
Agenda Agenda
2
Markets Served & Ambitions
Ambitions
• Benchmark company for Clean Fuels and Aromatics production,
• Leader in purification for olefins/polyolefins, syngas, refining and petrochemical, and natural gas streams,
• Innovator in the biodiesel market and syngas to liquids technology.
Business Units
Markets Served
3
Strongly Established in the Oil Refining Industry
~ 42% of worldwide running
oil refineries operate at least
one refining unit licensed by
Axens
~ 20% of worldwide consumption
of gasoline and on-road diesel is
produced by refining units licensed
by Axens
4
• Axens in brief
• Opportunities for Coal to Liquids
• Processes for Coal Liquefaction (Direct/Indirect)
• Guidelines for a choice & Economical data
Agenda Agenda
5
-5
5
15
25
35
45
Source: Axens & other sources (2010)
Indian Fuel demand 2010 - 2030
Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Petroleum
Coke, NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses, …
2010-2030
AAGR
Other* 2.1%
LPG 4.1%
Naphtha - 0.4%
Motor Gasoline 7.4%
Jet Kerosene 2.4%
On-road diesel 7.5%
Off-road diesel 4.7%
Fuel Oil 0.7%
MMTPA
Incremental Capacity 2010-2030
During this period, Indian middle distillate demand is expected to grow by 3.9% per year
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Why use coal to make fuels ?
• Energy Security • Extent of proven reserves • Geographic distribution of proven reserves
• Environmental performance • Clean Coal Technology • Possibility for CO2 capture
• Economic Performance • Crude oil price volatility • Competitive with alternatives • Market is there
7
Coal-to-Fuel: Challenges
Primary requirement: Increase hydrogen-to-carbon ratio to convert coal to liquid fuels
1.9 1.8 1.8
0.8
0
0.5
1
1.5
2
Gasoline Diesel CrudePetroleum
Coal
H/C Atomic Ratio
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Coal Liquefaction Routes
Fuels
CTL routes
DCL
H2
Coal
Syngas (CO+H2)
ICL
H2
Oil
ICL DCL Axens’ CTL Technology Gasel® H-Coal®
9
Agenda
• Axens in brief
• Opportunities for Coal to Liquids
• Processes for Coal Liquefaction (Direct/Indirect)
• Guidelines for a choice & Economical data
10
Principles of the DCL Route
Sulphur /
Ammonia
Liquefaction H-Coal®
Treatment
Refining H2
Liquid
Products
LPG
liquid
effluents
gaseous
effluents
Solid
Products
Solvent
CO2
Capture
Gasif. O2 Shift
AGR PSA
Raw
Syngas
Co
al
Typical Yield
3.5 to 4 bbl/ton maf
Preparation
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Axens H-Coal® Process
• Based on the H-Oil® process
• Used for the Conversion of the Heaviest petroleum
fractions to Distillate Liquid products
• First commercial unit in 1968, still in operation
• 14 H-Oil units licensed with a cumulated capacity of
584,000 BPSD
• H-Coal Development History
• Pilot plant development started in 1960s
• Scale-up to demonstration scale (200 TPD) in 1980s in
Catlettsburg, USA
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DCL Alliance
• Axens and Headwaters create a strategic alliance in January 2010
• Provides single-source solutions for ultra-clean fuels via Direct Coal Liquefaction (DCL)
• DCL applications can include coal-only or co-processing of coal with refinery residues and/or biomass
C T LO AL O IQ U ID S
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Hands-on Experience: Shenhua DCL Complex
World's Only Operating DCL Complex. Capacity: 6000t/day of coal / 22000 BPD of products. Start-up December 2008. 3 years in operation
The Most Advanced DCL Technology Available
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Raw
Syngas
Principles of ICL Route
Preparation
Gasif. Product
upgrading
H2
Liquid
Products: Naphtha
Jet
Diesel
CO2Capture
O2
Fischer-Tropsch Synthesis
H2 + CO
Purification
Axens Scope = Gasel® process
Raw Liquid
Effluents (FT waxes)
Typical Yield
2.5 to 3 bbl/ton maf
Co
al
Shift AGR PSA
Co-developers :
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Gasel® FT Synthesis
• Development and scale-up by Eni & IFP EN since 1996
• Low Temperature FT in a Slurry Bubble Column (SBC)
• 20 to 30 barg / 210-230°C
• Stable, robust, high throughputs
• FT Catalyst: Cobalt on Alumina powder
• Formulated and approved by Eni & IFP EN
• Developed and manufactured by Axens
• High activity and resistant to attrition
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Main items tested and proven on the 20 bpd unit:
• FT Catalyst Performance (activity, selectivity) in a real Slurry Bubble Column Reactor
• Pilot Process Scheme = Industrial Process Scheme
• External Liquid waxes/Solid catalyst separation
• Slurry handling
• Operational experience: 20,000 hours-on-stream since 2001
Fischer-Tropsch Pilot Plant
eni’s Sannazzaro Refinery Start-up in 2001
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FT Slurry Bubble Column Reactor
1. Gas flows upwards (~ plug flow)
2. inducing slurry recirculation
SBC system allows • Nearly isothermal conditions • High catalyst efficiency • High capacities per Reactor up to 15-20,000 bpd per Rx • On-line catalyst make-up
Gas bubbles
Slurry
Outlet
Offgas
Wax
Slurry
Return
Liquid
recirculation
Gas flow
Profile
Dense phase or slurry = Liquid + Catalyst
High Catalyst concentration
Syngas inlet
Catalyst concentration in the slurry and Operating Temperature are constant in the reactor
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ICL: Axens’ Integrated Offer
• Axens is the only technology licensor
• To offer a complete FT + Upgrading technology chain for the conversion of Syngas to Jet and Diesel
• To manufacture associated FT and Upgrading catalysts
• Gasel® selected for several XTL projects ranging from 2,000 to > 50,000 bpd, based upon its reliability, and strong R&D support
• Gasel® License awarded by ForestBtL for the
3,700 bpd Ajos BtL project in Finland (start-up in 2016)
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Agenda
• Axens in brief
• Opportunities for Coal to Liquids
• Processes for Coal Liquefaction (Direct/Indirect)
• Guidelines for a choice & Economical data
20
ICL / DCL: Choice of Technology Guidelines
Capex / Opex
Pro
du
ct y
ield
/ t
co
al
Ava
ilab
le C
oal
Qu
alit
y
DCL
ICL
10-20 %
1 b
arr
el/
ton
ma
f
Ash < 15%
H/C [0,7 – 0,8]
Desired Product Quality
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ICL / DCL: Product Split & Properties
• DCL distillates are naphthenic (good cold flow properties, average cetane, high density)
• ICL distillates are (iso-)paraffinic (very high cetane, good cold flow properties, low density)
Properties Ex-DCL Typical spec Ex-ICL/GTL
Density @ 15
C (kg/m3) 880 820 – 845 780
Cetane number (CN) 45-51 > 51 > 80
DCL ICL
Chemical
Nature
Aromatic Paraffinic
Density High Low
Cetane Average very High
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ICL and/or DCL ?
• Blending often required to fully tap product potential; Intelligence of target market required
• ICL + DCL can make on-spec products in a HCL hybrid scheme
• IRR improvement with HCL vs. ICL or DCL
Coal Preparation Coal
Coal Liquefaction
Gasification
Upgrading Section
F-T
H2
WGS
H2 Products
Axens expertise can help Project Decision 23
Conclusion
• Coal liquefaction is a strategic and economic alternative to importing oil for countries with significant coal reserves
• Choice between ICL and DCL routes is a case-by-case decision:
• Feedstock characteristics (Coal/Petcoke) – Ash, H/C, volatiles … and availability (capacity)
• Comparison of yields and economics for both routes
• Desired final product quality
• Axens is equipped with both ICL (Gasel®) and DCL (H-Coal®) technologies to help its Customers make the right choice
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