Indirect Coal Liquefaction Better Solution to Clean Energy System

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1 Indirect Coal Liquefaction Better Solution to Clean Energy System Yong-Wang Li, Director, Chief Scientist State Key Laboratory of Coal Conversion Institute of Coal Chemistry Chinese Academy of Sciences Taiyuan

2 Clean Energy system 2005 First Car Fueled by 100% F-T Super Clean Diesel EU III / 2.0L diesel engine Volks Wagen CADDY SDI 2.0 Economic fuel consumption ~5.0 L /100 km Cetane No. > 70 Extremely low S and N EU IV emission limit

3 Main points Energy status in China CTL solution CTL development in China Future development Summary

4 Energy status in China Coal Reserves Oil Gas 0 Million tons A B C Year Production in China 2020: 200 million tons/a Demands: A: 610 million tons/a B: 560 million tons/a C: 450 million tons/a Coal as major primary energy Oil insufficiency for the growing demands Solutions needed for sustainable development Gap: million tons/a

5 CTL Solution Coal Organic wastes Biomass Syngas production Syngas Purification Synthesis Highly Integrated System Power Generation CO 2 control NOW Electricity Liquid fuels Naphtha & Chemicals Hydrogen FUTURE CTL pointing to the sustainable solutions on the basis of GAIFICATION Less limited life span of CTL initialized production system

6 CTL Solution Fischer-Tropsch Synthesis Commercial scale operation SASOL HTFT gas-solid solid fluidized bed iron light fractions LTFT slurry phase /fixed bed iron and cobalt heavy fractions SHELL SMDS Fixed bed cobalt Technology in China: pilot plant proven iron (main) cobalt (in development) HFPT LFPT slurry phase-low temperature <250 o C heavy fractions slurry phase high high temperature o C diesel range high

7 CTL Development In China CTL in China: Brief history First BASF FTS technology Cobalt catalyst at normal pressure 74(X13ton) fixed bed reactors 30000ton Hydrocarbons/ a The plant was removed due to oil field discovery in 1960s in China

8 CTL Development In China : 1989: Development of iron catalysts Fixed bed reactor up to single tube tests. Slurry phase test in laboratory

9 CTL Development In China : 1993: 40 b /d demonstration plant test Fixed bed reactor with about 2000 tubes 1) Desulfurization was not adequate 2) Extremely low oil price

10 CTL Development In China New enhanced development initialized in 1997 Fischer-Tropsch synthesis in slurry phase

11 CTL Development In China FTS catalyst group Engineering group Fundamental Syncrude workingup

12 CTL Development In China FTS catalyst research and development - Iron based ICC-I I (heavy fraction) o C, slurry phase - Iron based ICC-II II (lighter fraction) o C, slurry phase - Cobalt based ICC-III III 220 o C~240 o C, slurry phase, fixed bed SPU W FSCP 70 Transmission (%) FM SE FM SD FM SC FM SB Conversion/Selectivity (%) CO con. H 2 con. CO+H 2 con. CH 4 sel. C 5 + sel. C 2 -C 4 = sel. 96 FM SA V e lo c ity (m m /s, re la tiv e to α -F e ) Time on stream (h)

13 CTL Development In China Process development and integration analysis - Simulation of Fischer-Tropsch loop for different catalyst systems - Hydrodynamics of slurry phase FT reactors and related - Pilot plant design & operation - Large scale slurry reactor design (4 m~ 8 m)

14 CTL Development In China Syncrude workup technology - New hydrogenation catalysts for hydrogenating FTS crudes - Cracking of FTS wax (new route) - Oligmerization of light olefins - Separation engineering

15 CTL Development In China Engineering fundamental - CFD calculation of three phase reactors - Quantum calculations on catalytic mechanism - Thermodymic data - Kinetics and reactor modeling

16 CTL Development In China Pilot plant Two types catalysts have been tested - Slurry phase reaction engineering well proved: reactor & related d process - Product working-up proved - Design package accomplished for the demonstration plant (3500 b/d) Demonstration plant (Synfuels( China+industries) - Iron catalyst + slurry phase reactor (~ 5.5m) - Dry fed entrained flow gasification (2 GSP ) - Diesel 70% Naphtha 18% LPG 12% - Possible IGCC scheme is considered (If governmental support got) - Efficiency ~ 43% Commercial action (Industries+government( Industries+government) - Two trains 3.2 million ton/year Shenhua Ningmei - Sasol technology (tendency) initializing

17 Preliminary results of the CTL diesel Index Co-Mo Mo-S Hy. Co-Mo Mo-S S Cr Ni Hy Density kg/l Viscosity mm2/s, 20 o C Initi.. boiling point o C Final boiling point o C Flash point o C Centane No >78-90 Total aromatics % Poly aromatics % Olefin % Sulfur ppm <4 <5 <0.5 CFPP o C Oxidation stability - - <0.3 mg/100ml Acidity <0.2mg KOH /100ml

18 CTL Future Development High selective catalysts development - Narrowing to middle distillates - Working at high temperature (280 o C) but in slurry phase - Optimizing factors affecting efficiency Reactor & processes - Enhancing reaction heat recovery ( 15% energy of syngas ) - Pressure up to 45 bars to increase single train productivity - Process integration optimization (co-production evaluation) - Water saving and treatment technologies New technology for syncrude up-grading - S free catalyst for hydrogenation & cracking - Light fraction utilization - New route for fuel production - Chemicals from syncrudes

19 CTL Future Development: Co-production (2) (1) Steam MP 50 tons ton ST coal Oxygen Nm ton ST coal Coal 1000 tons 6500 kcal/kg ST coal Electricity Steam (HP, MP,LP) (3) (7) (5) Electricity Steam (HP-MP) Electricity KWh 1200 tons KWh 9.9 ton ST coal ton ST coal ton ST coal (4) Syngas Nm 3 Syngas ton ST coal production (6) F-T synthesis Product upgrading Tail gas (9) (8) ton ST coal (10) Steam (LP-MP) 1883 tons ton ST coal Efficiency Oil 43-45% FTS thermal: 78-80%; CTL thermal: 63-65% Gasification thermal: 90% Oil products tons ton ST coal Energy points: Air separation & other unrecoverable: 15~25%. Recoverable: hot gas recovery 10%; tail gas 5.6%; reaction heat 15%.

20 Co-generation an introduction Electricity Efficiency (2) (1) Steam MP 50 tons ton ST coal Oxygen Nm ton ST coal Coal 1000 tons 6500 kcal/kg ST coal Steam (HP, MP,LP) (3) (7) (5) Electricity Steam (HP-MP) KWh 1200 tons 9.9 ton ST coal ton ST coal (4) Syngas Nm 3 Syngas ton ST coal production (6) F-T Product upgrading Electricity KWh ton ST coal Steam (LP-MP) 1883 tons ton ST coal (10) Oil_electricity 52-54% FTS thermal: 78-80%; CTL thermal: 63-65% Gasification thermal: 90% Oil products tons ton ST coal (8) (9) Tai gas ton ST coal (11) Steam 1200 tons (HP-MP) 1883 tons (LP) (12) IGCC Electricity MJ 99.1 ton ST coal Simple Co-production scheme can optimize the energy flows into valuable products

21 Summary CTL in whole has been well proved by large scale production and d is an important and practical option for China s s future liquid fuel supply. CTL route will bring us to a sustainable way in using our available able sources via syngas. CTL technology in China is approaching matured and will play important roles in the growing market. The super-clean diesel produced via CTL route will largely impose great benefits from environment improvement. Co-production solutions should be seriously considered.

22 Thanks for your attention

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