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Overview of Coal Liquefaction
James A. LepinskiVice PresidentHeadwaters IncorporatedU.S.-India Coal Working Group MeetingWashington, D.C.November 18, 2005
2
Headwaters at a GlanceCoal Value Chain
3Coal Liquefaction Technologies
• Direct Coal Liquefaction (DCL)• Indirect Coal Liquefaction (ICL)• Hybrid Coal Liquefaction (DCL/ICL)
4Direct Coal Liquefaction Process
RefiningCoal Liquefaction
Hydro-treating
Fractionation
C1 – C2
H2S, NH3, COx
Make-up Hydrogen
Coal + Catalyst
SlurrySlurry
H-Donor
Recycle H2
De-AshedOil (DAO)
Diesel FuelGasoline
LPG
Heavy VacuumGas Oil (HVGO)
Ash RejectSolventDe-ashing
Gas RecoveryTreatment
5Direct Coal Liquefaction Plants
Lawrenceville, NJ30 bpd
Catlettsburg, KY1800 bpd
Inner Mongolia, China17,000 bpd
6Indirect Coal Liquefaction Process
Gasification & Gas Cleaning
Oxygen/Steam
FT Synthesis
Iron Catalyst
Ultra-CleanLiquid Fuels& ChemicalFeedstocks
H2 + COSyngas
Waterand
Oxygenates
Coal*
Sulfur,CO2
and Ash
CxHyLiquids& Wax
FT ProductSeparation &
Upgrading
SteamElectricPower
Generation
Electricity
Steam Tail Gas
*Any carbon-bearing feedstock
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Indirect Coal Liquefaction Plant
Secunda, South Africa135,000 bpd
Brownsville, TX7,000 bpdGTL Plant
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Maximizing the Value of Coal
1 tonCoal*
Combustion
Polygeneration
Electricity ProductionProducts Value1.8 MWh electricity $72Total $72
Fuel and Power ProductionProducts Value 0.05 MWh electricity $20.17 bbls naphtha $81.29 bbls diesel fuel $100Total $110
A choice to make:
*Sub-bituminous coal as received basis
Fuel, Power & Fertilizer ProductionProducts Value
0.19 MWh electricity $80.18 bbls naphtha $90.96 bbls diesel fuel $750.18 t ammonium nitrate $63Total $155
Indirect Coal Liquefaction
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Comparison of DCL and ICL Economics (Based on Sub-bituminous Coal at $1/mm BTU)
Direct IndirectCapex for 50,000 bpd plant ($billion)* 3.3 3.3
Coal required for 50,000 bpd (stpd as rcvd) 23,000 32,000
Coal feedstock cost ($/bbl) 8 11
Opex excluding coal ($/bbl) 17 12
Return on investment @ 15% ($/bbl)** 30 30
Production cost including 15% ROI ($/bbl) 55 53
Crude oil equivalent ($/bbl) 41 40
For discussion purposes only.
* U.S. location. **100% equity basis
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Comparison of DCL and ICL Final ProductsDirect Indirect
Distillable product mix 65% diesel35% naphtha
80% diesel20% naphtha
Diesel cetane 42-47 70-75Diesel sulfur <5 ppm <1 ppmDiesel aromatics 4.8% <4%Diesel specific gravity 0.865 0.780Naphtha octane (RON) >100 45-75Naphtha sulfur <0.5 ppm NilNaphtha aromatics 5% 2%Naphtha specific gravity 0.764 0.673
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Hybrid DCL/ICL Plant Concept
Coal
Raw ICL products
Raw DCL products
H2
H2
FT tail gas
Final Products
CoalGasification
Indirect CoalLiquefaction
(FT)
Product Blending and
Refining
HydrogenRecovery
Direct Coal Liquefaction
12
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