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Indirect Coal Liquefaction
Shell Coal Gasification with
Fischer-Tropsch Synthesis
Karsten Radtke (speaker),Uhde GmbH (Germany)
John W. Rich Jr., Robert Hoppe, WMPI, Inc. (USA)
ThyssenKrupp GroupID102
Workforce: 185,000Sales: € 41 bn
Steel Automotive Elevator
Carbon Steel
Stainless Steel
SpecialMaterials
Body & Chassis(North America)
Body & Chassis(Europe/Asia/Pacific/Latin America)Powertrain(Global)
Steel Capital goods
Services
MaterialsServices Europe
Materials ServicesNorth America
IndustrialServices
Special Products
Services
Technologies
Uhde
Metal Cutting
PlantTechnology
Marine Systems
MechanicalEngineering
Transrapid
WMPI Project Waste Coal to Ultra Clean Liquid Fuels
Integration of three major blocks:1. Gasification of Waste Coal to Produce Synthesis Gas2. Conversion of Synthesis Gas using Fischer-Tropsch
Technology to Liquid Fuels3. Combustion of Tail Gas to produce Electric Power and
Steam
The Team
• Waste Management and Processors Inc. (Owner)
• Nexant (Owner’s Engineer)
• Shell Global Solutions (Licensor)
• Sasol Technology / ChevronTexaco (Licensor)
• Uhde (Engineering and turnkey contractor)
• Black & Veatch (Uhde’s U.S. gasification alliance partner)
WMPI, Inc.
U.S. Department of EnergyClean Coal Power Initiative (CCPI)
100,000,000 US-Dollars (granted)
National U.S. Energy Bill
WMPI Ultra Clean Fuels
Indirect Coal LiquefactionPlant
5,000 bpd
Diverse Support Mechanisms (pending)
Gasification PortfolioApplication defines Process
Shell SCGPKoppers-Totzek
Shell SGPHigh-Temperature Winkler
(HTW)
Winkler /HTW
Fluidized Bed
750-950 °C
< 30 bar
Dry Solid
1926 (Winkler)(Leuna)
WachtbergBerrenrath
Oulu Wesseling
40 Plants
Koppers-Totzek
Entrained Flow
1400-1600 °C
atm.
Dry Solid
1950 (Tippy Oy)
TalkhaNew Delhi
ModderfonteinMurphy Hill
77 Plants
Shell SCGP(Prenflo)
Entrained Flow
1500-1600 °C
25 - 45 bar
Dry Solid
1979(Hamburg)
FürstenhausenHouston
BuggenumPuertollano
5 Plants
Shell SGP
Entrained Flow
1300-1400 °C
35 - 65 bar
Liquid, Gas
Uhde‘s 1st: 1964(Belgium)
PernisLeunaHaldiaNangal
168 Plants
Process
Principle
Temp.
Pressure
Feeding
First Plants
Plants(Examples)
References
Uhde’s Gasification Portfolio
Shell Coal Gasification IGCC (253 MWe)Buggenum, The Netherlands
Coal/Biomass gasificationfor power generation
IGCC Puertollano 318 MWel, net
(feedstock: petcoke / coal)
Coal/Petcoke/Biomass gasificationfor power generation
Uhde‘s GTL/BTL/CTL Activities• WMPI - 5,000 bpd, SCPG + FT Synthesis: Uhde is selected EPC Contractor
• DKRW - 30,000 bpd, SCGP + FT Synthesis: Uhde is selected EPC Contractor
• 4 further U.S. projects (confidential) - 30.000 bpd each, SCGP + FT Synthesis:
Uhde is selected EPC Contractor
• German/Chinese Sustainable Fuel Partnership (GCSFP):
=> (German/Chinese governments, Shell, VW, BMW, DaimlerChrysler, BP,
Bosch, Uhde) - concepts include CTL, BTL, Biodiesel, Hydrogen)
• BTL Pilot Plant, IEC Freiberg: Engineering phase for modified HTW (PHTW)
based pilot plant - Methanol to Synfuel (MtS)
• Syntroleum: GTL Sweet Water Project, Basic Engineering
• UK Wesseling Methanol-to-Gasoline (Mobil MTG) plant at :
=> Brown Coal gasification to Gasoline (HTW + MTG)
• HTW Gasification for biomass (peat) to methanol, Oulo, Finland
• Direct Coal Liquefaction development (1970‘s) - not commercialised
Project Black Box
WMPICoal Liquefaction
Plant
Coal (Culm)
Air
Ultra Clean Fuels
Power
Slag
Sulfur
Flux
Fly Ash
Fischer Tropsch / Coal to Liquids
Gasification CO-Shift Acid GasRemoval
PSA
Coal
FischerTropsch
Heavy EndsRecovery
ProductWork-up
WaterTreatment
Gas TurbineSteam Syst.
Effluent Water
DieselNaphtha
Hydrogen
FT WAXFT Cond-
ensate
Internal Recycle
Power
Steam
FT-Reaction Chemistry:
CO + 2 H2 → -CH2- + H2O;∆H = - 165 kJ/mol
Fischer Tropsch - Products
1.) Ultra Clean Fuels (Naphtha, Diesel, Jet)
- High Cetane (> 70)
- Free of Sulfur (< 1ppm)
- Free of Aromatics (< 1ppm) and heavy metals
2.) Specialties
- Lube Oils
- Paraffins (e.g. for detergents, solvents etc.)
- Paraffin Waxes (e.g. for candles, colours, pharmaceuticals etc.)
Biomass
(e.g. 30 %)
Coal
(e.g. 70 %)
FeedstockPreparation
MillingGasification
Fischer-Tropsch
Synthesis
Ultra Clean Fuels ProductionFeedstock: Coal + Biomass
DieselBlending
Merchant “ultra clean”Biomass/Coal derived Diesel
Refinery
Syngas
Crude Oil DerivedDiesel
(e.g. 90 %)
F-T Diesel (e.g. 10 %)
Replacement ofNatural Gas with
Coal/Biomass derived Syngas XNatural Gas
Coal + Biomass=>
Ultra Clean Diesel Blend
Solids Processing
Raw Culm
Raw Tailings
+10” reject(Rock)
¾” reject(Rock)
28 mesh reject(Rock)
Culm / Tailings
Processing
Coal Milling &
DryingGasification
Slag fines
Fluxant
Fly ash
Slag
Petcoke
Raw gas
Coal Dust
¾” carbon
28 mesh carbon
Homogeneously mixed Feedstock
Shell SCGP Process Line-Up
DRY SOLIDSREMOVAL
WETSCRUBBING
Coal Feeding
MILLING/DRYING
MILLING AND DRYINGFLY ASH TO
HP STEAM
MP STEAM
Slag
COAL/PETCOKE FLY ASHRECIRC. QUENCH GAS
GASIFIER
SALTS SULPHUR
CLEAN
SYNGAS
WATERTREATMENT
900 °C
GAS TREATING
FLY ASH SYSTEM
1600 °C
Shell Coal Gasification Process (SCGP)Solid Feedstocks
Erection of the Coal/Petcoke Gasifierin Puertollano, Spain
Membrane Wall protected by the slag layer
Shell Coal/Coke Gasification SCGP
BFW, 40-70 bar
Water Tube(membrane wall)
Gasification Chamber > 1500 °C
molten slag flows downwards
solidified slagmolten slag
Project Benefits
•• Economical BenefitsEconomical Benefits1. Coal Production & Revitalization 2. Creating Jobs: Construction and Operating3. Energy Diversification & Independence
•• Environmental BenefitsEnvironmental Benefits1. Waste Utilization2. Ultra Clean Fuels3. Extreme low emissions from production and fuel use
Project Execution Structure
GasificationIsland
Syngas toLiquids Unit
DownstreamUnits
PowerBlock
ASU
Shell / Uhde
BasicEngineering
Krupp UhdeSingle Point Responsibility
Licensors
Basic Engineering
Sasol / ChevTx
Basic Engineering
B&V
BasicEngineering
Uhde & B&V - Task Force Detail Engineering, Procurement, Supervision, Commissioning
B&V - Civil and Erection
ASUVendor
Package Unit
Lump Sum Turn Key Contract
WMPI
Uhde / Black & Veatch Project Directorate
Single Point Responsibility
Utilities
B&V
BasicEngineering
Utilities
Summary
• Estimated net plant efficiency: 42%
• Economical & Marketable Fuels & Power
• Advanced Technologies for Future Needs
• Demonstrate Operability, Reliability